Research on machining deformation of aluminum alloy rolled ring induced by residual stress

Aluminum alloys are widely used in aerospace products because of their high specific stiffness and high specific strength. In the machining process of thin-walled aluminum ring workpieces, with the removal of materials, the stiffness of the parts decreases and the residual stress (RS) is released, resulting in obvious machining deformation (MD) of workpieces. Taking the typical 2219 aluminum alloy rolled ring as the research object, a new theoretical analysis model and a finite element model coupled with multi-physics and multi-processing are established to analyze the initial residual stress (IRS) distribution and the MD law. The accuracy of simulation prediction results regarding IRS and MD is verified by experiments, while the equivalent theoretical analytical model qualitatively explains the MD of the ring due to IRS. The IRS of the rolled ring is about 40 ~ 80 MPa, which induces a maximum MD of 0.4016 mm (from 89.9985 to 90.4001 mm) and an elliptical cross-section. The relative error of the MD result is 23.92%, while the ellipticity is only 11.30%.