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Measurement and Prediction of Machining Induced Redistribution of Residual Stress in the Aluminium Alloy 7449

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Abstract

The residual stress distributions in two 7449 aluminium alloy rectilinear blocks have been determined using neutron diffraction. Heat treatment included cold water immersion quenching and a period of precipitation hardening. Quenching induced very high magnitude residual stresses into the two blocks. One block was measured in this condition while the other was incrementally machined by milling to half thickness. Neutron diffraction measurements were made on the milled half thickness block at equivalent locations to the unmachined block. This permitted through thickness measurements from both blocks to be compared, revealing the redistribution of residual stresses induced by machining. A square cross section post in the centre of the machined face was left to act as a stress free reference sample. The distortions arising on the face opposite to that being milled were measured using a co-ordinate measuring machine. The residual stresses and distortion arising in the blocks have been compared to finite element analysis prediction and found to generally agree. Material removal only caused distortion and the residual stresses to redistribute; there was no stress relaxation evident.

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Acknowledgements

This investigation has been supported by the European Commission under the 6th Framework Programme project known as COMPACT (AST4-CT-2005-516078), which contributes to the thematic priority “Strengthening Competitiveness” of the European aircraft industry. The residual stress measurements conducted on the STRESS-SPEC instrument at FRM II have also been supported by the European Commission under the 6th Framework Programme through the Key Actions: Strengthening the European Research Area, Research Infrastructures. Contract n°: RII3-CT-2003-505925.

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Authors and Affiliations

  1. Materials Surface Science Institute, University of Limerick, Limerick, Ireland

    J. S. Robinson & D. A. Tanner

  2. Department of Mechanical Engineering, University of Bristol, Bristol, UK

    C. E. Truman

  3. Helmholtz Centre Berlin for Materials and Energy, Hahn Meitner Platz 1, Berlin, Germany

    R. C. Wimpory

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  1. J. S. Robinson
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  2. D. A. Tanner
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  3. C. E. Truman
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  4. R. C. Wimpory
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Correspondence to J. S. Robinson.

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Robinson, J.S., Tanner, D.A., Truman, C.E. et al. Measurement and Prediction of Machining Induced Redistribution of Residual Stress in the Aluminium Alloy 7449. Exp Mech 51, 981–993 (2011). https://doi.org/10.1007/s11340-010-9389-4

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  • DOI: https://doi.org/10.1007/s11340-010-9389-4

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