Investigation of surface residual stress distribution in deformation machining process for aluminum alloy

Abstract

Deformation machining is a combination of thin structure machining and single point incremental forming/bending. It enables the creation of monolithic structures with complex geometries in one setup, employing conventional manufacturing techniques. Previously, such components would either be assembled or manufactured using complex dies and machinery. Residual stresses generated during the machining and forming has direct implications on the product life cycle and properties. It is essential to understand the process effects on the residual stress distribution. In the present work, an experimental study of surface residual stress for deformation machining (bending and stretching mode) has been performed. The nano indentation technique has been employed to examine the residual stresses. The experimental results have shown the generation of compressive surface residual stresses during machining and tensile surface residual stresses during forming (bending and stretching) operations. Significant variation in the surface residual stresses with varying machining and forming parameters has been observed.