skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.

Explore Research Products in the PAR
It may take a few hours for recently added research products to appear in PAR search results.


  • NSF Public Access
  • Search Results
  • Intermethod comparison and evaluation of near surface residual stress in aluminum parts subject to various milling parameters
Title: Intermethod comparison and evaluation of near surface residual stress in aluminum parts subject to various milling parameters
Near surface residual stress (NSRS) induced by machining (e.g., milling) is known to drive distortion in machined aluminum, particularly in thin complex geometries with tight tolerance requirements where large distortion is undesirable. The understanding and characterization of NSRS in milled aluminum parts is important and should be included in the design and manufacturing process. There exist a variety of experimental tests characterizing these stresses. The objective of this paper is to assess the quality of three experimental methods for evaluating NSRS in prismatic aluminum parts subject to various milling parameters. The three methods are: hole-drilling, slotting, and x-ray diffraction, all of which include incremental material removal. The aluminum parts are cut from stress-relieved plate, AA7050-T7451. A combination of milling table and tool speeds are used to machine a flat surface in the parts. Measurements are made at specified locations and depths on each part. NSRS data from the hole drilling and slotting measurements were comparable; NSRS data from x-ray diffraction differed and was less repeatable. NSRS data for different milling parameters shows that the depth of NSRS increases with feed per tooth but is unaffected by different cutting speeds.  more » « less
Award ID(s):
1663341
PAR ID:
10137872
Author(s) / Creator(s):
; ;
Date Published:
Journal Name:
Residual Stress, Thermomechanics & Infrared Imaging and Inverse Problems, Volume 6; Proceedings of the 2019 Annual Conference on Experimental and Applied Mechanics
Volume:
6
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. ; ; ; ; ; ; (, Experimental Mechanics)
    Abstract Background While near surface residual stress (NSRS) from milling is a driver for distortion in aluminum parts there are few studies that directly compare available techniques for NSRS measurement. Objective We report application and assessment of four different techniques for evaluating residual stress versus depth in milled aluminum parts. Methods The four techniques are: hole-drilling, slotting, cos(α) x-ray diffraction (XRD), and sin 2 (ψ) XRD, all including incremental material removal to produce a stress versus depth profile. The milled aluminum parts are cut from stress-relieved plate, AA7050-T7451, with a range of table and tool speeds used to mill a large flat surface in several samples. NSRS measurements are made at specified locations on each sample. Results Resulting data show that NSRS from three techniques are in general agreement: hole-drilling, slotting, and sin 2 (ψ) XRD. At shallow depths (< 0.03 mm), sin 2 (ψ) XRD data have the best repeatability (< 15 MPa), but at larger depths (> 0.04 mm) hole-drilling and slotting have the best repeatability (< 10 MPa). NSRS data from cos(α) XRD differ from data provided by other techniques and the data are less repeatable. NSRS data for different milling parameters show that the depth of NSRS increases with feed per tooth and is unaffected by cutting speed. Conclusion Hole-drilling, slotting, and sin 2 (ψ) XRD provided comparable results when assessing milling-induced near surface residual stress in aluminum. Combining a simple distortion test, comprising removal of a 1 mm thick wafer at the milled surface, with a companion stress analysis showed that NSRS data from hole-drilling are most consistent with milling-induced distortion. 
    more » « less
  2. ; ; ; ; ; ; (, The International Journal of Advanced Manufacturing Technology)
    Abstract Machining-induced residual stresses (MIRS) are a main driver for distortion of thin-walled monolithic aluminum workpieces. Before one can develop compensation techniques to minimize distortion, the effect of machining on the MIRS has to be fully understood. This means that not only an investigation of the effect of different process parameters on the MIRS is important. In addition, the repeatability of the MIRS resulting from the same machining condition has to be considered. In past research, statistical confidence of MIRS of machined samples was not focused on. In this paper, the repeatability of the MIRS for different machining modes, consisting of a variation in feed per tooth and cutting speed, is investigated. Multiple hole-drilling measurements within one sample and on different samples, machined with the same parameter set, were part of the investigations. Besides, the effect of two different clamping strategies on the MIRS was investigated. The results show that an overall repeatability for MIRS is given for stable machining (between 16 and 34% repeatability standard deviation of maximum normal MIRS), whereas instable machining, detected by vibrations in the force signal, has worse repeatability (54%) independent of the used clamping strategy. Further experiments, where a 1-mm-thick wafer was removed at the milled surface, show the connection between MIRS and their distortion. A numerical stress analysis reveals that the measured stress data is consistent with machining-induced distortion across and within different machining modes. It was found that more and/or deeper MIRS cause more distortion. 
    more » « less
  3. ; ; ; ; ; (, The International Journal of Advanced Manufacturing Technology)
    Andrew Yeh-Ching Nee, editor-ion-chief (Ed.)
    Wire arc additive manufacturing (WAAM) has received increasing use in 3D printing because of its high deposition rates suitable for components with large and complex geometries. However, the lower forming accuracy of WAAM than other metal additive manufacturing methods has imposed limitations on manufacturing components with high precision. To resolve this issue, we herein implemented the hybrid manufacturing (HM) technique, which integrated WAAM and subtractive manufacturing (via a milling process), to attain high forming accuracy while taking advantage of both WAAM and the milling process. We describe in this paper the design of a robot-based HM platform in which the WAAM and CNC milling are integrated using two robotic arms: one for WAAM and the other for milling immediately following WAAM. The HM was demonstrated with a thin-walled aluminum 5356 component, which was inspected by X-ray micro-computed tomography (μCT) for porosity visualization. The temperature and cutting forces in the component under milling were acquired for analysis. The surface roughness of the aluminum component was measured to assess the surface quality. In addition, tensile specimens were cut from the components using wire electrical discharge machining (WEDM) for mechanical testing. Both machining quality and mechanical properties were found satisfactory; thus the robot-based HM platform was shown to be suitable for manufacturing high-quality aluminum parts. 
    more » « less
  4. ; ; ; (, RSC Mechanochemistry)
    Quininium aspirinate is mechanochemically prepared as a crystalline solid by liquid-assisted grinding, or as an amorphous phase (as determined by X-ray powder diffraction), by neat grinding or neat ball milling. Our previous work demonstrated using FT-IR spectroscopy that a mechanochemical reaction had occurred in the mechanically treated neat mixtures. Herein is reported that microcrystal electron diffraction (microED) afforded the discovery of two diffracting micron-size particles in the amorphous powder synthesized by manual grinding, among a majority of non-diffracting particles. Remarkably, microED data of one of them led to the known lattice parameters of quininium aspirinate. Furthermore, this so-called ‘X-ray amorphous’ phase quickly recrystallizes upon exposure to vapors of N,N-dimethylformamide, or hexane vapours (at a lower rate); but it remains amorphous for longer than 20 months when stored at ambient conditions in a closed container. The lattice parameters and the degrees of crystallinity of both recrystallized materials are identical within the experimental error. However, slightly more intense and better-resolved X-ray powder diffraction peaks are observed in the material recrystallized from N,N-dimethylformamide vapours than in the analogous phase recovered from hexane. As expected, Williamson–Hall graphs lead to a larger average crystalline domain size for the former solid. These results illustrate the use of microED for the investigation of structural features in amorphous phases, and the generic role of the solvent vapours in promoting their recrystallization. 
    more » « less
  5. ; ; ; ; ; ; ; ; ; ; et al (, AIP Advances)
    We report the experimental evidence of evolving lattice distortion in high quality epitaxial orthorhombic SrIrO3(001) thin films fully strained on (001) SrTiO3 substrates. Angle-resolved X-ray photoemission spectroscopy studies show that the surface layer of 5 nm SrIrO3 films is Sr–O terminated, and subsequent layers recover the semimetallic state, with the band structure consistent with an orthorhombic SrIrO3(001) having the lattice constant of the substrate. While there is no band folding in the experimental band structure, additional super-periodicity is evident in low energy electron diffraction measurements, suggesting the emergence of a transition layer with crystal symmetry evolving from the SrTiO3 substrate to the SrIrO3(001) surface. Our study sheds light on the misfit relaxation mechanism in epitaxial SrIrO3 thin films in the orthorhombic phase, which is metastable in bulk. 
    more » « less
  • Citation Formats
  • MLA
  • APA
  • Chicago
  • BibTeX
  • Save / Share this Record
  • Send to Email