An analytical model for predicting the machining deformation of a plate blank considers biaxial initial residual stresses

The initial residual stress in a blank is one of the main causes of machining deformation that has become a major concern in manufacturing aerospace monolithic structures. An analytical prediction model for machining deformation that considers biaxial residual stresses is proposed to investigate the quantitative relationship between deformation and initial residual stress. Finite element method (FEM) simulations and machining experiments are then conducted to validate the accuracy of the analytical model. Results calculated using the analytical model are consistent with the FEM and experiment results. Eventually, the quantitative relationships between deformation and initial residual stress under three typical machining strategies are determined. The effects of workpiece position in the blank on machining deformation are summarized based on these quantitative relationships.