Machining
of slender components in aluminum and titanium presents major difficulties in
terms of geometry and dimensional requirements. During the machining of this
type of components, non-conformances due to distortions are frequent due to the
residual stresses in the bulks, together with the machining induced stresses on
the surfaces. Currently it is common to find numerical models based on finite
element software that can estimate the final distortion of the component after
machining. These calculations are key when trying to adapt the machining
process to obtain components free of distortions. Despite representing a move
forward, these finite element models have limitations in their industrial
applicability due to the long computational times and poor usability. The
present work introduces an analytical simulation model of a machining process,
similar to the Layer Removal method, for the distortion prediction of machined
components. This analytical modeling tool considers the initial geometry of the
component, the residual stress profile of the bulk and the machining induced
surface stresses. Furthermore, to validate the analytical model a comparison
with finite element numerical model is presented, in terms of accuracy,
computational time and usability. The results obtained reflect important
benefits in favor of the analytical simulation model here presented, showing
its potential as an industrial tool to use when dealing with machining
distortions.
