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    A Wet Etching Method Coupled With Finite Element Analysis-Based Compliance Function to Determine Residual Stress in High-Speed Milling

    Source: Journal of Manufacturing Science and Engineering:;2006:;volume( 128 ):;issue: 003::page 792
    Author:
    Y. B. Guo
    ,
    M. E. Barkey
    ,
    S. C. Ammula
    DOI: 10.1115/1.2193550
    Publisher: The American Society of Mechanical Engineers (ASME)
    Abstract: High-speed milling (HSM) is widely used in the automotive and aerospace industries in fabricating mechanical components. HSM induced residual stress may significantly impact fatigue life and the corrosion resistance of machined components. Traditional methods of residual stress measurement are very time consuming and expensive. In this paper we presents a wet etching approach to obtain strain as a function of slot depth introduced in the subsurface. The strain readings were collected from a strain gauge mounted on the specimen surface near the slot edge. A compliance function can be conveniently calculated by simulating slot cutting using a finite element method via a Legendre polynomial subroutine as the applied load. The calculated compliance functions and measured strain values at different depths were used as inputs into a program to calculate residual stress. This leads to a faster and less expensive method of determining residual stress when compared with the traditional methods. The capability of this new approach was demonstrated by high-speed milling 6061-T651 and 7050-T7451 aluminum alloys. A design-of-experiment method was used to conduct milling tests with three levels of cutting speed, feed rate, and DOC. Residual stress profiles with 12 data points with the spatial resolution as small as 1μm in the subsurface were then obtained. Residual stress sensitivity to cutting conditions was investigated. In addition, subsurface microstructure and microhardness were also measured to characterize surface integrity in a broad sense.
    keyword(s): Stress , Finite element analysis , Cutting AND Chemical etching ,
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      A Wet Etching Method Coupled With Finite Element Analysis-Based Compliance Function to Determine Residual Stress in High-Speed Milling

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    http://yetl.yabesh.ir/yetl1/handle/yetl/134153
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    contributor authorY. B. Guo
    contributor authorM. E. Barkey
    contributor authorS. C. Ammula
    date accessioned2017-05-09T00:20:43Z
    date available2017-05-09T00:20:43Z
    date copyrightAugust, 2006
    date issued2006
    identifier issn1087-1357
    identifier otherJMSEFK-27953#792_1.pdf
    identifier urihttp://yetl.yabesh.ir/yetl/handle/yetl/134153
    description abstractHigh-speed milling (HSM) is widely used in the automotive and aerospace industries in fabricating mechanical components. HSM induced residual stress may significantly impact fatigue life and the corrosion resistance of machined components. Traditional methods of residual stress measurement are very time consuming and expensive. In this paper we presents a wet etching approach to obtain strain as a function of slot depth introduced in the subsurface. The strain readings were collected from a strain gauge mounted on the specimen surface near the slot edge. A compliance function can be conveniently calculated by simulating slot cutting using a finite element method via a Legendre polynomial subroutine as the applied load. The calculated compliance functions and measured strain values at different depths were used as inputs into a program to calculate residual stress. This leads to a faster and less expensive method of determining residual stress when compared with the traditional methods. The capability of this new approach was demonstrated by high-speed milling 6061-T651 and 7050-T7451 aluminum alloys. A design-of-experiment method was used to conduct milling tests with three levels of cutting speed, feed rate, and DOC. Residual stress profiles with 12 data points with the spatial resolution as small as 1μm in the subsurface were then obtained. Residual stress sensitivity to cutting conditions was investigated. In addition, subsurface microstructure and microhardness were also measured to characterize surface integrity in a broad sense.
    publisherThe American Society of Mechanical Engineers (ASME)
    titleA Wet Etching Method Coupled With Finite Element Analysis-Based Compliance Function to Determine Residual Stress in High-Speed Milling
    typeJournal Paper
    journal volume128
    journal issue3
    journal titleJournal of Manufacturing Science and Engineering
    identifier doi10.1115/1.2193550
    journal fristpage792
    journal lastpage801
    identifier eissn1528-8935
    keywordsStress
    keywordsFinite element analysis
    keywordsCutting AND Chemical etching
    treeJournal of Manufacturing Science and Engineering:;2006:;volume( 128 ):;issue: 003
    contenttypeFulltext
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