Residual stress test and simulation of incremental hole drilling method

Residual stress of thin-walled blanks with complex cavity structure is an important influence factor on the stability of machining. The most residual stress testing technologies is only suitable to measure residual stress of surface or shallow surface. It is difficult to ensure the accuracy to measure residual stress inside workpiece. In order to study the reliability and accuracy of incremental hole drilling method measuring interior residual stress, according to residual stress test for casting ZL205A aluminum alloy tapered thin-walled blank, finite element (FE) model with initial residual stress is established to simulate incremental hole drilling on the platform of ANSYS. Then error and the rationality of the finite element simulation model has been analyzed by comparing the simulation stress value with the test. The results indicate that the incremental hole drilling method has some errors to measures residual stress inside workpiece. The method is only suitable to measure surface residual stress.