Correcting distortions of thin-walled machined parts by machine hammer peening
Correcting distortions of thin-walled machined parts by machine hammer peening
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通过机锤喷丸校正薄壁机加工零件的变形
DOI：
10.1016/j.cja.2023.10.023
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发表时间：
2023
影响因子：
5.7
通讯作者：
MADARIAGA A
中科院分区：
文献类型：
--
作者：
MADARIAGA A
薄壁航空结构件在加工过程中经常发生变形。重新加工以纠正变形或最终拒绝零件大大增加了成本。本文提出了一种通过在加工零件的目标表面上有策略地施加锤击强化来纠正薄壁零件变形的新方法。本研究选用了7475-T7351铝合金。研究分为两个阶段。首先，对四种不同的气锤强化条件（改变步距和初始偏移量）所产生的残余应力（RS）进行了表征，并选择了其中一种条件作为下一阶段的试验条件。在第二阶段，采用有限元模型预测了典型工件的加工变形。然后，将锤击强化引起的变形纳入有限元模型，定义了两种不同覆盖面积的锤击强化策略，以分析其减少变形的能力。采用模拟锤击强化策略对两个工件进行了加工和处理，并进行了实验验证。试验结果表明，气锤强化可在800 μm深度内产生-50 ~ - 350 MPa的高压缩RS，且其强度随台阶距离的减小而增大。在代表性工件表面的4%以上进行锤击强化，使加工引起的变形减少了37%，100%的覆盖面积导致了五倍的过度修正。这证实了锤击强化可以战略性地应用（在目标区域和改变覆盖的百分比）来纠正低或严重的扭曲。
Thin-walled aerostructural components frequently get distorted after the machining process. Reworking to correct distortions or eventually rejecting parts significantly increases the cost. This paper proposes a new approach to correct distortions in thin-walled components by strategically applying hammer peening on target surfaces of a machined component. Aluminium alloy 7475-T7351 was chosen for this research. The study was divided in two stages. First, the residual stresses (RS) induced by four different pneumatic hammer peening conditions (modifying the stepover distance and initial offset) were characterised in a test coupon, and one of the conditions was selected for the next stage. In the second stage, a FEM model was used to predict distortions caused by machining in a representative workpiece. Then, the RS induced by hammer peening were included in an FEM model to define two hammer peening strategies (varying the coverage area) to analyse the capability to reduce distortions. Two workpieces were machined and then treated with the simulated hammer peening strategies for experimental validation. Results in the test coupon showed that pneumatic hammer peening can generate high compressive RS (-50 to −350 MPa) up to 800 μm depth, with their magnitude increasing with a reduced stepover distance. Application of hammer peening over 4 % of the surface of the representative workpiece reduced the machining-induced distortions by 37 %, and a coverage area of 100 % led to and overcorrection by a factor of five. This confirms that hammer peening can be strategically applied (in target areas and changing the percentage of coverage) to correct low or severe distortions.
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DOI：
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