Modelo analítico para la predicción de la distorsión en componentes mecanizados

Abstract

Machining of slender components in aluminum and titanium  presents major difficulties in terms of geometry and dimensional requirements. During the machining of this type  of components, non-conformances due to distortions are frequent due to the residual stresses in the bulks, together  with the machining induced stresses on the surfaces. Currently it is common to find numerical models based on  finite element software that can estimate the final distortion  of the component after machining. These calculations are  key when trying to adapt the machining process to obtain  components free of distortions. Despite representing a move  forward, these finite element models have limitations in their  industrial applicability due to the long computational times  and poor usability. The present work introduces an analytical  simulation model of a machining process, similar to the Layer  Removal method, for the distortion prediction of machined  components. This analytical modeling tool considers the initial geometry of the component, the residual stress profile of the  bulk and the machining induced surface stresses. Furthermore,  to validate the analytical model a comparison with finite  element numerical model is presented, in terms of accuracy,  computational time and usability. The results obtained reflect  important benefits in favor of the analytical simulation model  here presented, showing its potential as an industrial tool to  use when dealing with machining distortions.