On-machine Characterization of Bulk Residual Stresses on Machining Blanks

The manufacturing of ribbed aluminum structural parts presents several difficulties due to the appearance of geometrical distortions after machining. The presence of residual stresses on the aluminum blanks before machining is reported to be the main source of distortions for aluminum alloys. The variability of these stresses and the inability to measure them in every aluminum blank is the main limitation on the optimization of the machining processes of these parts. In this paper, a layer-removal based residual stress characterization method is proposed for its application in manufacturing environment. This method enables the identification of the bulk stresses on the machining blank and still allow the final machining of the component, making possible the definition of an optimized machining process that would yield a minimum component distortion.