Numerical investigation and modeling of residual stress field variability impacting the machining deformations of forged part

Abstract

Aluminum alloys are widely used for structural parts in the aerospace industry. Those parts are usually machined from rolled plates or forged blanks, and heat treatments are carried out to reach the necessary mechanical properties. Forming and heat treatments induce residual stresses that generate deformations during and after machining because material removal modifies their balance. One major issue in industry is the important variability of the residual stress field in forged blanks. A better knowledge of the residual stress field will enable the definition of better machining strategy to minimize the deformations. In order to understand and manage this variability, a sensibility analysis was performed to investigate the impact of their different potential sources. It relies on a coupling of 2D-FEM and beam model simulations. Then, this work introduces a model reduction technique (by POD and SVD) to build a model of the variability of a stress field and shows how it could be used on the production line.