Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets

Michael Ott, Moritz Mayer, Yiran Li, Florian Steinlehner, Michael F. Zaeh, Wolfram Volk

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

Residual stresses in metal components induced by forming operations significantly influence subsequent manufacturing steps. In particular, two aspects for the final processing of formed thick sheets by cutting and machining operations result: First, the achievable geometric accuracy is limited by distortion due to the modification of residual stresses across the process step sequence. In addition, the residual stresses present in the final component are determined by the process parameter settings of the individual substeps. In this work, the influence of the forming-induced residual stresses on a subsequent cutting operation was quantitatively investigated. For this purpose, the step sequence of forming and wet abrasive cutting for aluminum AA7075 thick sheets was implemented both numerically and experimentally. This allows the residual stress redistribution to be taken into account in future virtual setups of the production chain by specifically adjusting the process parameters.

Original languageEnglish
Title of host publicationProceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2
EditorsKatia Mocellin, Pierre-Olivier Bouchard, Régis Bigot, Tudor Balan
PublisherSpringer Science and Business Media Deutschland GmbH
Pages135-145
Number of pages11
ISBN (Print)9783031409196
DOIs
StatePublished - 2024
Event14th International Conference on Technology of Plasticity, ICTP 2023 - Mandelieu-La Napoule, France
Duration: 24 Sep 202329 Sep 2023

Publication series

NameLecture Notes in Mechanical Engineering
ISSN (Print)2195-4356
ISSN (Electronic)2195-4364

Conference

Conference14th International Conference on Technology of Plasticity, ICTP 2023
Country/TerritoryFrance
CityMandelieu-La Napoule
Period24/09/2329/09/23

Keywords

  • FEM
  • milling
  • residual stress
  • thick sheet forming

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