Finite element simulation and experimental investigation on the residual stress-related monolithic component deformation

The principal influence factors on the monolithic component deformation were investigated by finite element simulation simulation and experiment. Initial residual stress of the blank, machining-induced residual stress, and coupling action of these two effect factors were considered. To study the effect of blank initial residual stress on component deformation, chemical milling was used to remove the machining-induced residual stress on the machined surface of the components. The research results show that the initial residual stress in the blank was the main factor of deformation for three-frame monolithic beam, and the coupling action of the initial residual stress and machining-induced residual stresses aggravated the deformation. The deformation caused by machining residual stress accounted for about 10 % of the total deformation of the component, and the deformation caused by the blank initial residual stress accounted for 90 % of the total deformation of the component. The finite element simulation results were compared with experimental results and found to be in good agreement.