Simulation based reduction of residual stress related part distortion

During machining of structural components, material inherent stresses are removed and additional residual stresses are induced into the subsurface of the workpiece. Both effects may result in distortions of the workpiece leading to shape deviations and time consuming repair processes. The research objective of this paper is to reduce part distortion caused by residual stresses of machined aircraft components by utilizing a distortion simulation in advance. The presented method is able to predict the part distortion caused by initial and process induced residual stresses. The results are verified in an experimental setup by comparison of measured and predicted distortions of a structural part. Based on the simulated results two basic strategies to minimize part distortion are described. Both strategies have a high potential for direct transfer into industrial application. In addition, three more advanced strategies with the objective of zero distortion are presented.