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Journal Articles Journal of Manufacturing Processes Year : 2022

Direct Residual Stress Identification during Machining


Raw parts with high mechanical performances used for aeronautical workpieces are generally obtained by mechanical processes such as molding and/or forging. They mostly undergo additional heat treatments. These processes may induce mechanical residual stress within the material. During the machining step, residual stress are released when material is removed, which leads to initial stress distribution disruption. Thus, the workpiece deforms to satisfy the internal equilibrium, therefore requiring additional operations to be performed to fulfill dimensional and geometrical restrictions. A method has been developed here in order to identify residual stress maps within metal workpieces during machining. This method relies on the residual stress measuring method called “Layer Removal Method” and on a non-contact full-field measuring technique called “Digital Image Correlation”. This development aims at improving traditional residual stress measuring techniques and to realize measurements under harsh conditions, namely during machining. Compared to classical measuring methods, the proposed one involves several improvements such as being a non-contact and optical measurement and being performed continuously during the machining process. This novel approach allows the determination of the initial residual stress distribution across the depth by measuring the through-thickness workpiece displacement fields induced by the residual stress release during machining. A residual stress map within a Al7010-T7451 aluminum alloy beam with a magnitude order lying between −35 MPa and 34 MPa has been retrieved. Obtained results have been compared with literature- and Finite Elements results. This novel approach would ensure measurement of residual stress distributions of a part being machined, allowing monitoring and predicting, in real-time, part deflection. Therefore, adapting machining sequences in real-time would be possible to prevent undesirable deformations.
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Dates and versions

hal-03762822 , version 1 (29-08-2022)



Théo Jovani, Hélène Chanal, Benoît Blaysat, Michel Grédiac. Direct Residual Stress Identification during Machining. Journal of Manufacturing Processes, 2022, 82, pp.678-688. ⟨10.1016/j.jmapro.2022.08.015⟩. ⟨hal-03762822⟩
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