Numerical and experimental investigations of post-machining distortions in thin machined structures considering material-induced residual stress

Abstract

Post-machining part distortions are commonly observed in thin-walled machined structures. This problem is intensified if the machined part is cellular, curved in profile, and complex in design. Different customized techniques are executed to overcome this issue and to attain the desired dimensional accuracy. This problem instigates mainly due to redistribution of material-induced residual stress subsequent to machining operations. Research work presented here deals with numerical and experimental investigations of part distortions encountered in thin-walled machined structures. Computational analysis and manufacturing simulations of cutting operations are executed in ANSYS® software. Computational work is validated through actual experimentation on a computerized numerical controlled machine with optimum cutting parameters. Coordinate measuring machine (CMM) geometric inspection is carried out to determine the attained machining accuracy. Material-induced residual stress is developed through sequential coupled field thermo-mechanical analysis. Large-scale cutting simulations are performed in an optimized sequence by employing element birth–death feature. Simulation predicted distortions and CMM statistics is evaluated, and it was found that both corroborate with each other. This validates the approach adopted to predict part distortions.