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Modeling will help reduce machining problems and thereby enable more rapid introduction of high-performance materials and components. This article discusses the technical needs of aircraft engine and airframe structural components and modeling of heat-treat-induced residual stress by finite-element residual-stress analysis. It describes the two-dimensional (2-D) and three-dimensional (3-D) procedures involved in finite-element residual-stress analysis. The article deals with the 2-D and 3-D machining distortion validation on engine-disk-type components. It describes methods for obtaining machining-induced residual stresses, including detailed finite-element analysis of the cutting process, the simple fast-acting mechanistic model, and the semi-empirical linear stress model. The article concludes with information on the modeling benefits and implementation of modeling in a production environment.

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Kong Ma, Robert Goetz, Shesh K. Srivatsa, Modeling of Residual Stress and Machining Distortion in Aerospace Components, Metals Process Simulation, Vol 22B, ASM Handbook, Edited By D.U. Furrer, S.L. Semiatin, ASM International, 2010, p 386–407,

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