| Distortion and buckling of aluminum aerospace components can be caused by machining-induced residual stress or by residual stress induced earlier in material processing. This stress is characterized through layer removal experiments and measurements of surface location and X-ray diffraction. This stress is correlated to machining process parameters, which can be changed, in order to control distortion and buckling of machined metallic components. The finite element method is used to numerically predict distortion. Experiments are presented which compare distortion of machined parts to distortion of chemically milled parts in order to uncouple material bulk stress from machining induced stress. Methods are proposed to measure machining-induced and material bulk stress and predict the distortion of complex components. |
