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Open AccessArticle

Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal

1
Manufacturing Processes Group, IDEKO, 20870 Elgoibar, Spain
2
Department of Mechanical Engineering, Bilbao Faculty of Engineering, UPV-EHU, 48013 Bilbao, Spain
*
Author to whom correspondence should be addressed.
Materials 2020, 13(6), 1445; https://doi.org/10.3390/ma13061445
Received: 18 February 2020 / Revised: 17 March 2020 / Accepted: 19 March 2020 / Published: 22 March 2020
Prediction and control of machining distortion is a primary concern when manufacturing monolithic components due to the high scrap and rework costs involved. Bulk residual stresses, which vary from blank to blank, are a major factor of machining distortion. Thus, a bulk stress characterization is essential to reduce manufacturing costs linked to machining distortion. This paper proposes a method for bulk stress characterization on aluminium machining blanks, suitable for industrial application given its low requirements on equipment, labour expertise, and computation time. The method couples the effects of bulk residual stresses, machining stresses resulting from cutting loads on the surface and raw geometry of the blanks, and presents no size limitations. Experimental results confirm the capability of the proposed method to measure bulk residual stresses effectively and its practicality for industrial implementation. View Full-Text
Keywords: machining distortion; analytical modeling; layer removal; Al7050 T7451 alloy; multifactor coupling machining distortion; analytical modeling; layer removal; Al7050 T7451 alloy; multifactor coupling
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MDPI and ACS Style

Aurrekoetxea, M.; López de Lacalle, L.N.; Llanos, I. Machining Stresses and Initial Geometry on Bulk Residual Stresses Characterization by On-Machine Layer Removal. Materials 2020, 13, 1445.

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