Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses
In this paper, the effects of material removal strategies and initial stress states on the machining deformation of aluminum alloy plates were investigated through a combination of finite element simulation and experiments. We developed different machining strategies described by Tm+Bn, which remova...
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MDPI AG
2023-03-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/5/2033 |
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| author | Yang Li Ya-Nan Li Xi-Wu Li Kai Zhu Yong-An Zhang Zhi-Hui Li Hong-Wei Yan Kai Wen |
| author_facet | Yang Li Ya-Nan Li Xi-Wu Li Kai Zhu Yong-An Zhang Zhi-Hui Li Hong-Wei Yan Kai Wen |
| author_sort | Yang Li |
| collection | DOAJ |
| description | In this paper, the effects of material removal strategies and initial stress states on the machining deformation of aluminum alloy plates were investigated through a combination of finite element simulation and experiments. We developed different machining strategies described by Tm+Bn, which removal m mm materials form top and n mm materials from the bottom of the plate. The results demonstrate that the maximum deformation of structural components with the T10+B0 machining strategy could reach 1.94 mm, whereas with the T3+B7 machining strategy was only 0.065 mm, decreasing by more than 95%. The asymmetric initial stress state had a significant impact on the machining deformation of the thick plate. The machined deformation of thick plates increased with the increase in the initial stress state. The concavity of the thick plates changed with the T3+B7 machining strategy due to the asymmetry of the stress level. The deformation of frame parts was smaller when the frame opening was facing the high-stress level surface during machining than when it was facing the low-stress level. Moreover, the modeling results for the stress state and machining deformation were accurate and in good accordance with the experimental findings. |
| first_indexed | 2024-03-11T07:18:12Z |
| format | Article |
| id | doaj.art-0bdaa341939c492da14af3152b21a6fd |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T07:18:12Z |
| publishDate | 2023-03-01 |
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| spelling | doaj.art-0bdaa341939c492da14af3152b21a6fd2023-11-17T08:06:20ZengMDPI AGMaterials1996-19442023-03-01165203310.3390/ma16052033Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual StressesYang Li0Ya-Nan Li1Xi-Wu Li2Kai Zhu3Yong-An Zhang4Zhi-Hui Li5Hong-Wei Yan6Kai Wen7State Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaState Key Laboratory of Nonferrous Metals and Processes, GRINM Group Co., Ltd., Beijing 100088, ChinaIn this paper, the effects of material removal strategies and initial stress states on the machining deformation of aluminum alloy plates were investigated through a combination of finite element simulation and experiments. We developed different machining strategies described by Tm+Bn, which removal m mm materials form top and n mm materials from the bottom of the plate. The results demonstrate that the maximum deformation of structural components with the T10+B0 machining strategy could reach 1.94 mm, whereas with the T3+B7 machining strategy was only 0.065 mm, decreasing by more than 95%. The asymmetric initial stress state had a significant impact on the machining deformation of the thick plate. The machined deformation of thick plates increased with the increase in the initial stress state. The concavity of the thick plates changed with the T3+B7 machining strategy due to the asymmetry of the stress level. The deformation of frame parts was smaller when the frame opening was facing the high-stress level surface during machining than when it was facing the low-stress level. Moreover, the modeling results for the stress state and machining deformation were accurate and in good accordance with the experimental findings.https://www.mdpi.com/1996-1944/16/5/2033aluminum alloymaterial removal strategymachining deformationfinite element simulationasymmetric residual stress |
| spellingShingle | Yang Li Ya-Nan Li Xi-Wu Li Kai Zhu Yong-An Zhang Zhi-Hui Li Hong-Wei Yan Kai Wen Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses Materials aluminum alloy material removal strategy machining deformation finite element simulation asymmetric residual stress |
| title | Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses |
| title_full | Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses |
| title_fullStr | Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses |
| title_full_unstemmed | Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses |
| title_short | Influence of Material Removal Strategy on Machining Deformation of Aluminum Plates with Asymmetric Residual Stresses |
| title_sort | influence of material removal strategy on machining deformation of aluminum plates with asymmetric residual stresses |
| topic | aluminum alloy material removal strategy machining deformation finite element simulation asymmetric residual stress |
| url | https://www.mdpi.com/1996-1944/16/5/2033 |
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