Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components

Garimella Sridhar; Ramesh Babu Poosa

doi:doi:10.11648/j.ijmea.20150305.12

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Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components

Garimella Sridhar, Ramesh Babu Poosa

Published in International Journal of Mechanical Engineering and Applications (Volume 3, Issue 5)

Received: 2 August 2015 Accepted: 10 August 2015 Published: 19 August 2015

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Abstract

Thin wall thin floor monolithic components produced from prismatic blocks are machined on CNC machines by removing material up to 95 %. Components distort because of stresses induced due to severe heat generated and plastic deformation during cutting. Distortion of the components after machining aluminium alloys is major problem faced in aerospace and automobile industries. The volume of the material removed has direct bearing on machining time, which may lead to distortion. The objective of this study is to determine the effect of volume of material removal on the distortion of aluminium 2014 T651 alloy machined from prismatic block. Machining experiments were carried out with 5 different blank sizes to produce a representative component with same machining parameters. Distortion is measured on the face opposite to the machined surface and maximum deviations were used for comparisons between distortion and volume of material removal

Published in	International Journal of Mechanical Engineering and Applications (Volume 3, Issue 5)
DOI	10.11648/j.ijmea.20150305.12
Page(s)	86-93
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2015. Published by Science Publishing Group

Keywords

Volume of Material Removal, Distortion, Blank Size

References

[1]	Sridhar, Garimella, and P. Ramesh Babu. "Understanding the challenges in machining thin walled thin floored Avionics components, " International Journal of Applied Science and Engineering Research 2.1: 93-100, 2013.
[2]	Stephenson, D. A., Agapiou, J. S., Metal Cutting Theory and Practice, Second Edition, CRC, Boca Raton, FL, 568-9, 2006.
[3]	Marusich T. D., D. A. Stephenson, S. Usui, and S. Lankalapalli, "Modeling Capabilities for Part Distortion Management for Machined Components." Third Wave Systems (2009).
[4]	Totten, George E., and D. Scott MacKenzie, eds. Handbook of Aluminum: Vol. 1: Physical Metallurgy and Processes. Vol. 1. CRC Press, 2003.
[5]	Chatelain, Jean-François, Jean-François Lalonde, and Antoine S. Tahan, "Effect of Residual Stresses Embedded within Workpieces on the Distortion of Parts after Machining," International Journal of Mechanics 6: 43-5, 2012.
[6]	Cui, Hengbo, Jong-Yun Jung, and Dug-Hee Moon, "The Selection of Machining Parameters to Minimize Deformation caused by Heat," Proceedings of the Fall Conference of Society of Korea Industrial and Systems Engineering, Korea. 2005.
[7]	DONG, Hui-yue, and Ying-lin KE, "Study on machining deformation of aircraft monolithic component by FEM and experiment," Chinese Journal of Aeronautics 19.3: 247-254, 2006.
[8]	Lalonde, J. F., M. A. Gharghouri, and J. F. Chatelain, "Effect of Residual Stresses on the Distortion of Components after Machining.", NRC-CNBC Annual Report 2007.
[9]	Younger, Mandy S., and Kenneth H. Eckelmeyer. "Overcoming residual stresses and machining distortion in the production of aluminium alloy satellite boxes," Sandia Report SAND2007-6811, Sandia National Laboratories, 2007.
[10]	Denkena, B., and L. de León, "Machining induced residual stress in wrought aluminium parts, " Proceedings of 2nd International Conference on Distortion Engineering. 2008.
[11]	Belgasim, O., and M. H. El-Axir, "Modeling of residual stresses induced in machining aluminum magnesium alloy (Al–3Mg)," Proceedings of the world congress on engineering, Vol. 2. 2010.
[12]	Garimella Sridhar and P. Ramesh Babu, "Cutting Parameter Optimization for Minimizing Machining Distortion of Thin Wall Thin Floor Avionic Components using Taguchi Technique", International Journal of Mechanical Engineering & Technology (IJMET).Volume:4,Issue:4,Pages:71-78, 2013.
[13]	Keleshian, N., et al., "On the distortion and warpage of 7249 aluminum alloy after quenching and machining," Journal of materials engineering and performance 20.7: 1230-1234, 2011.
[14]	Songtao Wang, Zheng Minli, Fan Yihang, and Li Zhe, "Cutting Parameters Optimization in Machining Thin-Walled Characteristics of Aircraft Engine Architecture based on Machining Deformation," Advances in Information Sciences & Service Sciences 4.10, 2012.
[15]	Huang, Xiaoming, et al., "An Experimental Investigation of Residual Stresses in High-Speed End Milling 7050-T7451 Aluminum Alloy," Advances in Mechanical Engineering, 2013.
[16]	Huang, Xiaoming, Jie Sun, and Jianfeng Li, "Effect of Initial Residual Stress and Machining-Induced Residual Stress on the Deformation of Aluminium Alloy Plate," Strojniški vestnik-Journal of Mechanical Engineering 61.2: 131-137, 2015.
[17]	Ma, K., R. Goetz, and S. K. Srivatsa. "Modeling of residual stress and machining distortion in aerospace components." ASM Handbook 22, 2010.

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APA Style

Garimella Sridhar, Ramesh Babu Poosa. (2015). Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components. International Journal of Mechanical Engineering and Applications, 3(5), 86-93. https://doi.org/10.11648/j.ijmea.20150305.12

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ACS Style

Garimella Sridhar; Ramesh Babu Poosa. Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components. Int. J. Mech. Eng. Appl. 2015, 3(5), 86-93. doi: 10.11648/j.ijmea.20150305.12

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AMA Style

Garimella Sridhar, Ramesh Babu Poosa. Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components. Int J Mech Eng Appl. 2015;3(5):86-93. doi: 10.11648/j.ijmea.20150305.12

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@article{10.11648/j.ijmea.20150305.12,
  author = {Garimella Sridhar and Ramesh Babu Poosa},
  title = {Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {3},
  number = {5},
  pages = {86-93},
  doi = {10.11648/j.ijmea.20150305.12},
  url = {https://doi.org/10.11648/j.ijmea.20150305.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20150305.12},
  abstract = {Thin wall thin floor monolithic components produced from prismatic blocks are machined on CNC machines by removing material up to 95 %. Components distort because of stresses induced due to severe heat generated and plastic deformation during cutting. Distortion of the components after machining aluminium alloys is major problem faced in aerospace and automobile industries. The volume of the material removed has direct bearing on machining time, which may lead to distortion. The objective of this study is to determine the effect of volume of material removal on the distortion of aluminium 2014 T651 alloy machined from prismatic block. Machining experiments were carried out with 5 different blank sizes to produce a representative component with same machining parameters. Distortion is measured on the face opposite to the machined surface and maximum deviations were used for comparisons between distortion and volume of material removal},
 year = {2015}
}

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TY  - JOUR
T1  - Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components
AU  - Garimella Sridhar
AU  - Ramesh Babu Poosa
Y1  - 2015/08/19
PY  - 2015
N1  - https://doi.org/10.11648/j.ijmea.20150305.12
DO  - 10.11648/j.ijmea.20150305.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 86
EP  - 93
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20150305.12
AB  - Thin wall thin floor monolithic components produced from prismatic blocks are machined on CNC machines by removing material up to 95 %. Components distort because of stresses induced due to severe heat generated and plastic deformation during cutting. Distortion of the components after machining aluminium alloys is major problem faced in aerospace and automobile industries. The volume of the material removed has direct bearing on machining time, which may lead to distortion. The objective of this study is to determine the effect of volume of material removal on the distortion of aluminium 2014 T651 alloy machined from prismatic block. Machining experiments were carried out with 5 different blank sizes to produce a representative component with same machining parameters. Distortion is measured on the face opposite to the machined surface and maximum deviations were used for comparisons between distortion and volume of material removal
VL  - 3
IS  - 5
ER  -

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Author Information

Garimella Sridhar

Department of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad, India
Ramesh Babu Poosa

Department of Mechanical Engineering, University College of Engineering, Osmania University, Hyderabad, India

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APA Style

Garimella Sridhar, Ramesh Babu Poosa. (2015). Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components. International Journal of Mechanical Engineering and Applications, 3(5), 86-93. https://doi.org/10.11648/j.ijmea.20150305.12

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ACS Style

Garimella Sridhar; Ramesh Babu Poosa. Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components. Int. J. Mech. Eng. Appl. 2015, 3(5), 86-93. doi: 10.11648/j.ijmea.20150305.12

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AMA Style

Garimella Sridhar, Ramesh Babu Poosa. Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components. Int J Mech Eng Appl. 2015;3(5):86-93. doi: 10.11648/j.ijmea.20150305.12

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@article{10.11648/j.ijmea.20150305.12,
  author = {Garimella Sridhar and Ramesh Babu Poosa},
  title = {Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {3},
  number = {5},
  pages = {86-93},
  doi = {10.11648/j.ijmea.20150305.12},
  url = {https://doi.org/10.11648/j.ijmea.20150305.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20150305.12},
  abstract = {Thin wall thin floor monolithic components produced from prismatic blocks are machined on CNC machines by removing material up to 95 %. Components distort because of stresses induced due to severe heat generated and plastic deformation during cutting. Distortion of the components after machining aluminium alloys is major problem faced in aerospace and automobile industries. The volume of the material removed has direct bearing on machining time, which may lead to distortion. The objective of this study is to determine the effect of volume of material removal on the distortion of aluminium 2014 T651 alloy machined from prismatic block. Machining experiments were carried out with 5 different blank sizes to produce a representative component with same machining parameters. Distortion is measured on the face opposite to the machined surface and maximum deviations were used for comparisons between distortion and volume of material removal},
 year = {2015}
}

Copy | Download

TY  - JOUR
T1  - Volume of Material Removal on Distortion in Machining Thin Wall Thin Floor Components
AU  - Garimella Sridhar
AU  - Ramesh Babu Poosa
Y1  - 2015/08/19
PY  - 2015
N1  - https://doi.org/10.11648/j.ijmea.20150305.12
DO  - 10.11648/j.ijmea.20150305.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 86
EP  - 93
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20150305.12
AB  - Thin wall thin floor monolithic components produced from prismatic blocks are machined on CNC machines by removing material up to 95 %. Components distort because of stresses induced due to severe heat generated and plastic deformation during cutting. Distortion of the components after machining aluminium alloys is major problem faced in aerospace and automobile industries. The volume of the material removed has direct bearing on machining time, which may lead to distortion. The objective of this study is to determine the effect of volume of material removal on the distortion of aluminium 2014 T651 alloy machined from prismatic block. Machining experiments were carried out with 5 different blank sizes to produce a representative component with same machining parameters. Distortion is measured on the face opposite to the machined surface and maximum deviations were used for comparisons between distortion and volume of material removal
VL  - 3
IS  - 5
ER  -

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