| A mathematical model for the prediction of distortion of parts machined from aluminum plates (in particular 7050-T7451 aluminum plates), caused by the bulk (or material) stresses, together with its resultant residual stress state is given. The proposed model is studied as the simplest model of a hierarchical model structure, its predictive capabilities are evaluated by following the verification and validation processes, consisting in assessment of numerical accuracy and experimental correlation. The good correlation between the numerical simulation and the experimental results imply that the proposed model provides an efficient tool to estimate the distortion and residual stress field of a part machined from aluminum plates, when the machining induced stress can be considered negligible. It is proven that, under this condition, the distortion of a part depends exclusively on the stress distribution within the plate and the shape and the through thickness location of the part. Therefore, the final distortion of a part can be predicted considering the initial state (i.e., the residual stress in the plate) and the final state (i.e., the shape and location of the machined part). Furthermore, a procedure to reduce the distortion caused by machining-induces stress is proposed. |
