Hostname: page-component-586b7cd67f-gb8f7 Total loading time: 0 Render date: 2024-11-28T05:16:39.063Z Has data issue: false hasContentIssue false
  • English
  • Français

Accurate measurement of the surface residual stresses generated by milling in pre-equilibrium state

Published online by Cambridge University Press:  14 June 2016

Longhui Meng ,
Maen Atli ,
Yinfei Yang  and
Ning He
Longhui Meng*
Affiliation:
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016, China
Maen Atli*
Affiliation:
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016, China
Yinfei Yang*
Affiliation:
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016, China
Ning He
Affiliation:
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu 210016, China
*
b) e-mail: [email protected]
c) e-mail: [email protected]
a) Address all correspondence to these authors. e-mail: [email protected]
Get access

Abstract

We introduce a method to measure accurately surface residual stresses in the pre-equilibrium state, which were generated in workpieces during the milling process. The method takes into account strain changes and uses the inverse calculation. Material in the stress layer was removed layer by layer, and the strain change on the opposite side of the machined surface was measured. We also consider the change of the bending moment caused by the changed neutral layer. The stress values were calculated from the last layer to the first layer, and the residual stresses generated by milling are measured. We created a finite element model of a real workpiece and the measured stress values were used as inputs for the model. The measuring method was validated using finite element analysis. We find that our measuring method can be successfully used in practice to measure surface residual stresses and it provides reliable indicators for evaluating the surface properties of machined workpieces.

Keywords

stress/strain relationshipsimulationsurface chemistry
Type
Articles
Information
Journal of Materials Research , Volume 31 , Issue 14 , 28 July 2016 , pp. 2076 - 2087
Copyright
Copyright © Materials Research Society 2016 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

Contributing Editor: Jürgen Eckert

References

REFERENCES

Wang, J.J., Shang, S.Z., Lu, G.M., and Yu, J.G.: Viscosity estimation of semi-solid alloys based on thermal simulation compression tests. Int. J. Mater. Res. 104, 255 (2013).Google Scholar
Wang, J.J., Brabazon, D., Phillion, A.B., and Lu, G.M.: An innovative two-stage reheating process for wrought aluminum alloy during thixoforming. Metall. Mater. Trans. A 46, 4191 (2015).CrossRefGoogle Scholar
Navas, V.G., Gonzalo, O., and Bengoetxea, I.: Effect of cutting parameters in the surface residual stresses generated by turning in AISI 4340 steel. Int. J. Mach. Tools Manuf. 61, 48 (2012).CrossRefGoogle Scholar
Sebastiani, M., Eberl, C., Bemporad, E., and Pharr, G.M.: Depth-resolved residual stress analysis of thin coatings by a new FIB–DIC method. Mater. Sci. Eng., A 528, 7901 (2011).CrossRefGoogle Scholar
Mainjot, A.K., Schajer, G.S., Vanheusden, A.J., and Sadoun, M.J.: Residual stress measurement in veneering ceramic by hole-drilling. Dent. Mater. 27, 439 (2011).CrossRefGoogle ScholarPubMed
Carrera, E., Rodríguez, A., Talamantes-Silva, J., Gloria, D., Valtierra, S., and Colás, R.: Study of residual stresses in complex aluminium castings. Int. J. Cast Met. Res. 25, 264 (2012).CrossRefGoogle Scholar
Rossini, N.S., Dassisti, M., Benyounis, K.Y., and Olabi, A.G.: Methods of measuring residual stresses in components. Mater. Des. 35, 572 (2012).CrossRefGoogle Scholar
Arrazola, P.J., Kortabarria, A., Madariaga, A., Esnaola, J.A., Fernandez, E., Cappellini, C., Ulutan, D., and Özel, T.: On the machining induced residual stresses in IN718 nickel-based alloy: Experiments and predictions with finite element simulation. Simulat. Model. Pract. Theor. 41, 87 (2014).CrossRefGoogle Scholar
Singh, A. and Agrawal, A.: Investigation of surface residual stress distribution in deformation machining process for aluminum alloy. J. Mater. Process. Technol. 225, 195 (2015).CrossRefGoogle Scholar
Mann, P., Miao, H.Y., Gariépy, A., Lévesque, M., and Chromik, R.R.: Residual stress near single shot peening impingements determined by nanoindentation and numerical simulations. J. Mater. Sci. 50, 2284 (2015).CrossRefGoogle Scholar
Brinksmeier, E. and Sölter, J.: Prediction of shape deviations in machining. CIRP Ann.—Manuf. Technol. 58, 507 (2009).CrossRefGoogle Scholar
Meng, L., He, N., Li, L., Yang, Y., and Zhao, W.: Measurement of the residual stress induced by milling in TC4 workpiece before self-balancing and its FEA. Rare Metal Mater. Eng. 43, 1991 (2014).Google Scholar
Meng, L., He, N., Yang, Y., and Zhao, W.: Measurement of surface residual stresses generated by turning thin-wall Ti6Al4V tubes using different cutting parameters. Rare Metal Mater. Eng. 44, 2381 (2015).Google Scholar
Meng, L., He, N., and Li, L.: Calculation of residual stress induced by machining in internal surface of TC4 tubular parts and its FEA. China Mech. Eng. 25, 2583 (2014).Google Scholar
Meng, L., He, N., Yang, Y., Zhao, W., and Rong, B.: Method for measuring residual stresses induced by boring in internal surface of tube and its validation with XRD method. Trans. Nanjing Univ. Aeronaut. Astronaut. 31, 508 (2014).Google Scholar
Meng, L., He, N., Yang, Y., and Zhao, W.: Application of FEM correction to measuring the surface residual stresses generated by turning Ti6Al4V tube parts. J. Harbin Inst. Technol. 47, 71 (2015).Google Scholar
Yin, M., Liao, G., Wen, Q., and Cheng, H.: Chemical milling process for 2219 aluminum alloy tube. Mater. Prot. 38, 24 (2006).Google Scholar
Zhu, X., Wu, L., and Zheng, H.: The analytic method of Nat S in chemical milling solution. Mater. Coat. Electroplating 4, 40 (2006).Google Scholar