Effect of Initial Residual Stress and Machining-Induced Residual Stress on the Deformation of Aluminium Alloy Plate

During the machining of aerospace thin-walled components, a large amount material is removed, and machining-induced residual stress is induced in the boundary layer of the work piece, which results in deformation of the components. In this study, the effects of material initial residual stress and machining-induced residual stress on the deformation of aluminium alloy plate are studied. A theoretical model of the plate is analysed first, and the experiments of the milling deformation under different initial residual stress conditions are performed. The results show that the machining-induced residual stress is the primary factor of distortion. The coupling action of compressive initial residual stress and machining-induced residual stress increase the plate deformation, and the coupling action of tensile initial residual stress and machining-induced residual stress decrease the plate deformation. The finite element simulation results are compared with experimental results and found to be in good agreement