Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Seger, Michael; Mathews, Ritin; Marais, Deon; Venter, Andrew M.; Halley, Jeremiah; Wang, Jyhwen; Malik, Arif

doi:10.1115/1.4066155

Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Journal Article · Thu Aug 29 00:00:00 EDT 2024 · Journal of Manufacturing Science and Engineering

DOI:https://doi.org/10.1115/1.4066155· OSTI ID:2448191

Seger, Michael ^[1]; ^[2]; Marais, Deon ^[3]; Venter, Andrew M. ^[3]; Halley, Jeremiah ^[4]; Wang, Jyhwen ^[5]; Malik, Arif ^[1]

Univ. of Texas at Dallas, Richardson, TX (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
South African Nuclear Energy Corporation (Necsa), North West Province (South Africa)
ADDMAN Precision, Wright City, MO (United States)
Texas A & M Univ., College Station, TX (United States)

Dimensional tolerances for high-speed-machined aluminum products continue to tighten due to the demand for automated assembly of complex monolithic parts in aerospace and other industries. Understanding the contribution of inherent residual stress in wrought Al 7050-T7451 plate, common in aircraft manufacture, to distortion of high-aspect-ratio machined parts is critical but remains problematic due to the alloy's low residual stress magnitude over large geometries. Prior investigations into residual stress effects on machined part distortion suffer inadequate characterizations of the wrought material stress field, either because of low fidelity due to “slitting” methods, confounding effects in machined-layer removal methods, or small sample size when using neutron diffraction (ND). In this work, inherent residual stress is measured via ND at 860 locations in a 90.5 mm thick Al 7050-T7451 plate having dimensions 399 mm in the rolling direction and 335 mm in the transverse direction. Unlike prior studies, the ND residual stress is reconstructed using an iterative algorithm to ensure fully compatible, equilibrated 3D field prior to examining its effect on distortion. Further, the findings from simulations and experiments show that inherent residual stress alone could distort a high-aspect-ratio part beyond aerospace industry requirements, that slitting measurements may not sufficiently characterize residual stress for predicted distortion, and that parts machined from different plate thickness locations could exhibit reversed distortion patterns. Thus, research into distortion prediction that considers machining should carefully characterize and reconstruct inherent residual stress so that the coupled machining effects are accurately modeled.

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This content will become publicly available on Fri Aug 29 00:00:00 EDT 2025

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; National Science Foundation (NSF)

Grant/Contract Number:: AC05-00OR22725; CMMI-1762722

OSTI ID:: 2448191

Journal Information:: Journal of Manufacturing Science and Engineering, Vol. 146, Issue 10; ISSN 1087-1357

Publisher:: ASMECopyright Statement

Country of Publication:: United States

Language:: English

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