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

doi:10.1007/978-3-031-40920-2_15

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

Technical University of Munich

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-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 language	English
Title of host publication	Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2
Editors	Katia Mocellin, Pierre-Olivier Bouchard, Régis Bigot, Tudor Balan
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	135-145
Number of pages	11
ISBN (Print)	9783031409196
DOIs	https://doi.org/10.1007/978-3-031-40920-2_15
State	Published - 2024
Event	14th International Conference on Technology of Plasticity, ICTP 2023 - Mandelieu-La Napoule, France Duration: 24 Sep 2023 → 29 Sep 2023

Publication series

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

Conference

Conference	14th International Conference on Technology of Plasticity, ICTP 2023
Country/Territory	France
City	Mandelieu-La Napoule
Period	24/09/23 → 29/09/23

Keywords

FEM
milling
residual stress
thick sheet forming

Access to Document

10.1007/978-3-031-40920-2_15

Cite this

Ott, M., Mayer, M., Li, Y., Steinlehner, F., Zaeh, M. F., & Volk, W. (2024). Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets. In K. Mocellin, P.-O. Bouchard, R. Bigot, & T. Balan (Eds.), Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2 (pp. 135-145). (Lecture Notes in Mechanical Engineering). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-031-40920-2_15

Ott, Michael ; Mayer, Moritz ; Li, Yiran et al. / Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets. Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2. editor / Katia Mocellin ; Pierre-Olivier Bouchard ; Régis Bigot ; Tudor Balan. Springer Science and Business Media Deutschland GmbH, 2024. pp. 135-145 (Lecture Notes in Mechanical Engineering).

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

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.",

keywords = "FEM, milling, residual stress, thick sheet forming",

author = "Michael Ott and Moritz Mayer and Yiran Li and Florian Steinlehner and Zaeh, {Michael F.} and Wolfram Volk",

note = "Publisher Copyright: {\textcopyright} 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.; 14th International Conference on Technology of Plasticity, ICTP 2023 ; Conference date: 24-09-2023 Through 29-09-2023",

year = "2024",

doi = "10.1007/978-3-031-40920-2_15",

language = "English",

isbn = "9783031409196",

series = "Lecture Notes in Mechanical Engineering",

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editor = "Katia Mocellin and Pierre-Olivier Bouchard and R{\'e}gis Bigot and Tudor Balan",

booktitle = "Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2",

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Ott, M, Mayer, M, Li, Y, Steinlehner, F, Zaeh, MF & Volk, W 2024, Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets. in K Mocellin, P-O Bouchard, R Bigot & T Balan (eds), Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2. Lecture Notes in Mechanical Engineering, Springer Science and Business Media Deutschland GmbH, pp. 135-145, 14th International Conference on Technology of Plasticity, ICTP 2023, Mandelieu-La Napoule, France, 24/09/23. https://doi.org/10.1007/978-3-031-40920-2_15

Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets. / Ott, Michael; Mayer, Moritz; Li, Yiran et al.
Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2. ed. / Katia Mocellin; Pierre-Olivier Bouchard; Régis Bigot; Tudor Balan. Springer Science and Business Media Deutschland GmbH, 2024. p. 135-145 (Lecture Notes in Mechanical Engineering).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets

AU - Ott, Michael

AU - Mayer, Moritz

AU - Li, Yiran

AU - Steinlehner, Florian

AU - Zaeh, Michael F.

AU - Volk, Wolfram

PY - 2024

Y1 - 2024

N2 - 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.

AB - 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.

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BT - Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2

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ER -

Ott M, Mayer M, Li Y, Steinlehner F, Zaeh MF , Volk W. Quantification of the Impact of Forming-Induced Residual Stresses on Subsequent Cutting Operations for Aluminum AA7075 Thick Sheets. In Mocellin K, Bouchard PO, Bigot R, Balan T, editors, Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity - ICTP 2023 - Volume 2. Springer Science and Business Media Deutschland GmbH. 2024. p. 135-145. (Lecture Notes in Mechanical Engineering). doi: 10.1007/978-3-031-40920-2_15

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

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Keywords

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