Prediction and measurement of machining distortion in aluminium alloy 7085

It is essential to accurately predict or model the residual stresses in a material resulting from various manufacturing operations. Numerical methods were used in this study to predict the residual stresses after quenching and cold compression of an Al 7085 forged block. Experimental verification was provided by comparing the measured distortions due to a relaxation of the residual stresses with the predictions obtained by using a simulated stress field. The validation was carried out on a simplified structural part. The measured and simulated distortions were found to be in good agreement with each other. The results indicated that part distortion is attributable to the relaxation of bulk residual stresses.