Title of Project
On using finite element analysis (FEA) to control and minimize the growth of residual stress during machining
Name of Advisor/s
Dr Greg Wheatley, A/Prof Dimitry Sediako (Uni of British Colombia)
College of Science & Engineering
Summary of Project
The distortion in machining aerospace aluminium alloy parts is one of the serious challenges in satellite industries. The residual stresses caused by various manufacturing processes are the main cause. In order to get a comprehensive understanding of the problems about residual stresses and distortion in machining of 6082 and 7075 aluminium alloys, several aspects should be taken into account including the main reasons of residual stress; the factors influencing distortion during machining, the measurement methods of residual stresses and the prediction and controlling methods of distortion. In addition, the mechanism of the bulk residual stress inner materials and the machining-induced residual stresses must be considered as well as the influences of residual stresses and machining process conditions on distortion. Furthermore, the common residual stress measurement methods and its application scope must be addressed. However, differences, advantages, and disadvantages of various prediction methods are significant elements. These methods are used for controlling distortion before and after machining. Aluminium alloys are formed through several steps such as casting, rolling, forging, heat treatments, and machining. Accordingly, residual stresses can be categorized to bulk residual stress inner materials before machining and surface residual stresses after machining. In order to solve the distortion problem, this project focuses on fundamental research and investigation of distortion caused by residual stresses in machining aerospace aluminium alloys 6082 and 7075 parts. This study will focus on a fundamental base for industries to optimize and improve current manufacturing process of these alloys to reduce residual stress during machining. This work will help us to better understand and develop physically based computer models by using finite element analysis (FEA) to control and minimize the growth of residual stress during machining.
Machining, Residual Stress, finite element analysis (FEA)
Would suit an applicant who
has a sound academic background, research experience, an interest in mechanical engineering and strong experimental and computational skills.