Improving accuracy of bulk residual stress characterization in ribbed geometries through equivalent bending stiffness
Year: 2021
Type: article
Abstract: Machining distortion control is of great concern to the manufacturing of slender aerospace components. Simulation models for distortion prediction enable forecasting potential distortion as material is removed and bulk stresses released. These models, either analytical or numerical, require accurate residual stress data as it varies from one machining blank to another. The on-machine layer removal method is a promising technique for fulfilling the task due to its low requirements on equipment, labor expertise, and computation time, which enable industrial application. Besides, the method can be applied to ribbed geometries allowing to measure the stresses and obtain the final component from the same bulk, just by taking certain assumptions related to its geometry. Nevertheless, under these assumptions the method does not consider the bucking of the ribs or their specific position within the components, which decreases its accuracy in ribbed geometries. In this paper, the influence of equivalent bending stiffness in the characterization of residual stresses of machining blanks for ribbed components is investigated. The formulation considers through-thickness bulk residual stresses and machining-induced residual stresses in two spatial directions, as well as the initial curvature of the machining blanks. A semi-analytical formulation establishes the quantitative relation between source and distortion for ribbed part geometries. Finally, simulations are contrasted with experimental data in a Al 7050-T7451 demonstrator.
Source: Procedia CIRP
Institutions: Ideko (Spain), University of the Basque Country
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: diamond
Award: G7767650609
OpenAlex ID: W3204945693