Machining FEA & Residual Stress
Budget: $250 – $750 USD
I want detailed finite-element models that capture the thermo-mechanical behaviour of 7075-T6 during CNC milling, turning and drilling. Abaqus, deform or similar software must be used for every step of the workflow so I can reproduce and extend the study later.
Scope
• Build geometrically accurate 3-D models for each cutting process, apply realistic tool–workpiece interaction, and define temperature-dependent material data for 7075-T6.
• Run coupled stress–thermal simulations; vibration response is not required.
-After the machining process, residual stress and temperature on the part will be examined.
• For milling, go a step further: extract and map residual stresses through the depth of the workpiece, then correlate them with the predicted deformations so I can understand part distortion after machining.
Deliverables
• Abaqus or similar input files and associated job files for milling, turning and drilling.
• Post-processed contour plots of temperature, von Mises stress, and residual stress distributions, plus a deformed-shape result set.
• A concise report (PDF or Word) describing the modelling assumptions, boundary conditions, mesh sensitivity checks and key findings, with screenshots that match the contour plots.
• A short read-me on how to rerun the analyses.
Acceptance
I will consider the project complete when I can import your input files into Abaqus/CAE, rerun the jobs without errors, and see residual-stress values in the milling model that match those shown in your report within ±5 %.
Scope
• Build geometrically accurate 3-D models for each cutting process, apply realistic tool–workpiece interaction, and define temperature-dependent material data for 7075-T6.
• Run coupled stress–thermal simulations; vibration response is not required.
-After the machining process, residual stress and temperature on the part will be examined.
• For milling, go a step further: extract and map residual stresses through the depth of the workpiece, then correlate them with the predicted deformations so I can understand part distortion after machining.
Deliverables
• Abaqus or similar input files and associated job files for milling, turning and drilling.
• Post-processed contour plots of temperature, von Mises stress, and residual stress distributions, plus a deformed-shape result set.
• A concise report (PDF or Word) describing the modelling assumptions, boundary conditions, mesh sensitivity checks and key findings, with screenshots that match the contour plots.
• A short read-me on how to rerun the analyses.
Acceptance
I will consider the project complete when I can import your input files into Abaqus/CAE, rerun the jobs without errors, and see residual-stress values in the milling model that match those shown in your report within ±5 %.