A numerical procedure for machining distortions simulation on a SAF 2507 casting workpiece

The workpiece distortion that occurs during machining, can lead to a large increase in the number of the scrap parts. Residual stresses are the main cause of these distortions and they are generally present in both forging and casting products. In order to obtain the desired microstructure and mechanical properties, the workpiece is subjected to heat treatment before being worked. Quenching produces residual stresses that exist throughout a large percentage of the casting or forging part. Distortion occurs as a result of removing stressed material from the workpiece. The component will re-equilibrate and distort as each layer of stressed material is machined away. This paper describes a procedure development for distortions numerical analysis on a SAF2507 casting bulk workpiece. A solubilization heat treatment has been simulated, in order to predict the bulk residual stresses distribution. Different metal cutting processes have been considered to measure the numerical distortions induced in the workpiece