scholarly journals Aluminum alloys for satellite boxes : engineering guidelines for obtaining adequate strength while minimizing residual stresses and machining distortion.

2007 ◽  
Author(s):  
Mandy S. Younger ◽  
Kenneth Hall Eckelmeyer
Keyword(s):  
Aluminum Alloys ◽  
Residual Stresses ◽  
Machining Distortion

Study on the Residual Stresses Distribution in Thick Pre-Stretched Aluminum Plate

2018 ◽  
Vol 764 ◽  
pp. 49-57
Author(s):  
Hun Guo ◽  
Dun Wen Zuo ◽  
Fei Hong Yin ◽  
Ya Feng He ◽  
Ji Xu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Quantitative Analysis ◽  
Residual Stresses ◽  
Thick Plate ◽  
Engineering Application ◽  
Machining Distortion ◽  
Stress Strain Relation ◽  
Measurement Results ◽  
Aluminum Plates

It is one of the difficult problems in the manufacture of the integrated aircraft part of Machining distortion caused by residual stress. According to the characteristics of aluminum alloy pre stretched thick plate, the modified removal method for measuring residual stress in thick pre-stretched aluminum plates is proposed and the stress-strain relation matrix is deduced by elasticity theory. Moreover, the residual stresses in the specimen of 7075T7351 plate is measured by the proposed method, and the results are finally analyzed and compared with the data obtained by other methods. The results indicate that the proposed method is effective in measuring the residual stress in thick pre-stretched aluminum alloy plates. The measurement results can be used for the quantitative analysis of aerospace parts machining distortion caused by residual stress, and it has higher value in engineering application.

FEA-Based Comparative Investigation on High Speed Machining of Aluminum Alloys AA6061-T6 and AA7075-T651

2017 ◽  
Vol 261 ◽  
pp. 347-353 ◽  
Author(s):  
Walid Jomaa ◽  
Victor Songmene ◽  
Philippe Bocher ◽  
Augustin Gakwaya
Keyword(s):  
Aluminum Alloys ◽  
Residual Stresses ◽  
Chip Formation ◽  
High Speed ◽  
Cutting Temperature ◽  
Numerical Data ◽  
Formation Mechanisms ◽  
High Speed Machining ◽  
Machined Surface ◽  
Initial Yield Stress

Independent research studies have shown notable dissimilarity in the machining behaviour of aluminum alloys AA6061−T6 and AA7075−T651 commonly used in automotive and aeronautical applications. The present work attempts to investigate this dissimilarity based on experimental and numerical data with a focus on chip formation and generated residual stresses under similar high−speed machining (HSM) conditions. The numerical data were calculated by a finite element modeling (FEM) developed using DeformTM 2D software. The results showed that both studied alloys exhibit different chip formation mechanisms and residual stress states at the machined surfaces. On one hand, the AA6061−T6 alloy generates continuous chips and tensile residual stresses whereas the AA7075−T651 alloy produces segmented chips and compressive residual stresses. FEM results showed that the AA6061−T6 alloy generates lower cutting temperature at the tool−chip interface along with higher equivalent total strains at the machined surface as compared to the AA7075−T651 alloy. Based on the experimental and numerical results, it was pointed out that the differences in terms of thermal conductivity and initial yield stress are the main reasons explaining the dissimilarity observed.

scholarly journals FORMULATION OF STRESS-STRAIN RELATIONS OF STRUCTURAL ALUMINUM ALLOYS AND OF RESIDUAL STRESSES INDUCED BY JOINING

2008 ◽  
Vol 64 (4) ◽  
pp. 789-805
Author(s):  
Ichiro OKURA ◽  
Takashi NAGAO ◽  
Toshiyuki ISHIKAWA ◽  
Nobuyasu HAGISAWA ◽  
Shimpei OSUMI
Keyword(s):  
Aluminum Alloys ◽  
Residual Stresses ◽  
Stress Strain

Effects of Ultrasonic Deep Rolling on Fatigue Performance of Pre-Corroded 7A52 Aluminum Alloy

2011 ◽  
Vol 189-193 ◽  
pp. 897-900 ◽  
Author(s):  
Xiong Lin Ye ◽  
You Li Zhu ◽  
Dong Hu Zhang
Keyword(s):  
Aluminum Alloy ◽  
Fatigue Life ◽  
Aluminum Alloys ◽  
Residual Stresses ◽  
Fatigue Behavior ◽  
Fatigue Performance ◽  
Deep Rolling ◽  
Fatigue Crack Nucleation ◽  
7A52 Aluminum Alloy ◽  
Compressive Residual Stresses

The effects of ultrasonic deep rolling (UDR) on the fatigue behavior of pre-corroded 7A52 aluminum alloys were investigated. By means of X-Ray diffraction stress measurements and scanning electron microscopy (SEM), residual stress and fractograph of 7A52 aluminum alloys with and without UDR treatment were analyzed. The results indicated that the UDR produced compressive residual stresses with depth approaching 1mm. UDR treatment can extend the fatigue life of the pre-corroded 7A52 specimens to a large extent, depending on the level of corrosion and UDR parameter. For the slightly corrode specimens, the UDR treatment changed the fatigue crack nucleation site from surface to the transition zone between the compressive residual stresses and tensile stresses, resulted in a much longer fatigue life. For the severely corrode specimens, the crack still nucleated by intergranular cracking, however, due to the compressive residual stresses introduced and the closure of the corrosion pits and corrosion micro-crocks, UDR treatment still improved fatigue performance of the pre-corroded 7A52 aluminum alloy substantially.

scholarly journals The finite cell method for the prediction of machining distortion caused by initial residual stresses in milling

Procedia CIRP ◽  
2021 ◽  
Vol 102 ◽  
pp. 144-149
Author(s):  
M. Landwehr ◽  
S. Schmid ◽  
V. Holla ◽  
P. Ganser ◽  
T. Bergs ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Finite Cell Method ◽  
Cell Method ◽  
Machining Distortion ◽  
Finite Cell

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

Materials ◽  
2020 ◽  
Vol 13 (6) ◽  
pp. 1445 ◽  
Author(s):  
Maria Aurrekoetxea ◽  
Luis Norberto López de Lacalle ◽  
Iñigo Llanos
Keyword(s):  
Residual Stresses ◽  
Computation Time ◽  
Primary Concern ◽  
Industrial Implementation ◽  
Machining Distortion ◽  
Bulk Stress ◽  
Prediction And Control ◽  
And Control ◽  
Monolithic Components ◽  
Initial Geometry

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.

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