Simulation of the coupling effect of bulk and induced residual stresses on machining distortion

During high performance machining of large thin walled aluminum aerospace parts, significant distortions become visible. These distortions are due to the effect of the residual stress redistribution, it is therefore critical to understand the influence of residual stresses on machining distortions. This paper presents the prediction of machining distortions on a demonstration part caused due to the combination of bulk and measured induced residual stresses using interpolation techniques into a FE software. The FE model was then compared with CMM data where the FE model predicted the trend and the magnitude with a small difference of around 3%.