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A new method for inferencing and representing workpiece residual stress field using monitored deformation force data

A new method for inferencing and representing workpiece residual stress field using monitored deformation force data

Zhao, Zhiwei, Liu, Changqing, Li, Yingguang and Gao, Xiaoyu ORCID: 0000-0001-5625-3654 (2022) A new method for inferencing and representing workpiece residual stress field using monitored deformation force data. Engineering. ISSN 2095-8099 (Print), 2096-0026 (Online) (In Press)

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Abstract

The residual stress inside stock materials is one of the fundamental properties related to the quality of manufactured parts, in terms of geometric/dimensional stability and fatigue life. For parts of large size and high precision requirements, accurate measuring and predicting the residual stress field has been a major challenge. Existing technologies to measure residual stress field are either strain-based measurement methods or non-destructive methods with low efficiency and accuracy. This paper reports a new non-destructive method for inferencing the residual stress field based on deformation forces. The residual stress field of a workpiece was inferred based on the characteristics that the deformation forces reflected the overall effect of unbalanced residual stress field after material removal operations. The relationship between deformation forces and the residual stress field was modeled based on the principle of virtual work, and the residual stress field inference problem was solved by an enforced regularization method. The theoretical verification is presented and actual experiment cases tested, shown reliable accuracy and flexibility for large aviation structural parts. The underlying principle of the method provides an important reference for predicting and compensating workpiece deformation caused by residual stress using dynamic machining monitoring data in the digital and intelligent manufacturing context.

Item Type: Article
Uncontrolled Keywords: residual stress field; precision manufacturing; deformation force; inverse problem; in-situ measurement
Subjects: T Technology > TJ Mechanical engineering and machinery
Faculty / School / Research Centre / Research Group: Faculty of Engineering & Science
Faculty of Engineering & Science > Design, Manufacturing and Innovative Products Research Theme
Faculty of Engineering & Science > School of Engineering (ENG)
Last Modified: 06 Jul 2022 08:24
URI: http://gala.gre.ac.uk/id/eprint/36805

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