Prediction of residual stress induced distortions in micro-milling of Al7050 thin plate

In this paper, a new analytical model based on a mechanistic force prediction and elastoplastic relaxation procedure predicting the deflections induced by the residual stresses in a milled micro part is proposed. The force model defines the Hertzian type distribution applied by the tool on the part. The proposed deflection model is valid for thin rectangular parts typically produced only using a micro-milling process. The deflection and the force model were analytically developed and experimentally tested on thin Al 7050 micro plates. The force model was validated using micro dynamometer and the deflection profile was verified using the white light interferometer. The proposed model showed that it has a reasonable ability to predict the residual stress induced deflection in the context of stress gradient and intensity.