Materials-affected manufacturing in precision machining

Abstract

The influence of different microstructural attributes on the material properties such strength, hardness, residual stress or other physical properties are very well understood. During the manufacturing of mechanical parts utilized in important industries such as energy, aerospace or biomedical, the effect of the processing in term of thermal and mechanical loading is very important as it is directly influencing the microstructure evolution and the properties. The understanding of how the manufacturing process such as high precision machining will affect first the microstructure and therefore the part properties. In this work, we propose the Materials-Affected Manufacturing (MAM). It is a new paradigm helping to understand the interaction between the manufacturing process parameters, materials microstructure attributes and the properties. This is solved using a computational approach using an iterative blending to relate different models. Residual stresses are also studied. An enhanced analytical model is proposed. The model is capable for the first time to predict analytically the residual stress regeneration in the multi-step machining problem. An enhancement of the existing model is proposed. The (MAM) method was applied to the case of turning process of Aluminum 7075. The average grain size and the crystallographic texture were predicted and validated experimentally. The residual stress regeneration was computed for the case of milling of Aluminum 2024. Experimental validations using X-ray technique were performed for validations.