Research on Machining Distortion due to Residual Stresses of Large Monolithic Beam


Article Preview

Machining-induced distortion of large monolithic parts with thin walled structures creates problems in aircraft manufacturing industry. Typical monolithic beams of airframe are machined by NC machine and machining distortions are recorded. Thin walled structures are prone to distortions and dimensional instabilities due to internal stresses; therefore, stress-relieved vibration method is applied to reduce the internal stresses in blank material and results in better machining performance and dimension stability. But vibration stress-relief method doesn’t work always due to unknown reasons. Machining simulations in ANSYS are performed to predict the residual stress-induced machining distortion and simulation result is compared with the machining measurements to validate the simulation process. Cutting simulations have been executed by the element deactivation technique after developing the initial residual stresses via sequential coupled field analysis. The possibility of residual stress being relieved more reasonably and less distortion by optimized machining sequence through simulation is discussed.



Advanced Materials Research (Volumes 433-440)

Edited by:

Cai Suo Zhang




Y. Q. Wang et al., "Research on Machining Distortion due to Residual Stresses of Large Monolithic Beam", Advanced Materials Research, Vols. 433-440, pp. 530-537, 2012

Online since:

January 2012




[1] Keith A. Young. Machining-induced residual stress and distortion of thin parts[D]. U.S.A.: Washiongton University , (2005).

[2] Mura T., Micro-mechanics of defects in solids [M], Martinus Nickoff, publishers, Netherlands, (1982).

[3] Kang Xiaoming, Sun Jie, Su Caimao, et al. Sources and Control of Machining Distortions in Large Integral Structures[J]. China Mechanical Engineering, Vol. 15, No. 13.

[4] Jaroslav Mackerle. Finite element analysis and simulation of quenching and other heat treatment processes-A bibliography (1976–2001)[J]. Computational Materials Science, 2003, (27): 313–332.


[5] He Ning, Wang Zhigang, Jiang Chengyu, et al. Finite element method analysis and control stratagem for machining deformation of thin-walled components[J]. Journal of Materials Processing Technology, 2003, (139) : 332-336.


[6] Wang Zhaojun , Chen Wuyi , Zhang Yidu, et al. Study On the Machining Distortion of Thin Walled Part Caused by Redistribution of Residual Stress [J], Chinese journal of aeronautics, Vol. 18, No. 2.

[7] Wang, Sheng Ping, Padmanaban, Shivakumar, A New Approach for FEM Simulation of NC Machining Processes [C], 8th International Conference on Numerical Methods in Industrial Forming Processes. AIP Conference Proceedings, Vol712, pp.1371-1376.


[8] NCNR 2003 Annual Report, Residual Stresses and Optimizing Machining Strategies for Aluminum Bars [R], NIST center for neutron research, http: /www. ncnr. nist. gov/AnnualReport/FY2003_html/RH15.


[9] Yu Wei, X. W. Wang , Computer simulation and experimental study of machining deflection due to original residual stress of aerospace thin-walled parts, The international journal of advanced manufacturing technology, 2007, Vol 33, No 3-4, pp.260-265.


Fetching data from Crossref.
This may take some time to load.