AI-based residual stress prediction and machining path optimization

Residual stress generated during material manufacturing and post-processing critically affects the dimensional accuracy of aerostructure components. In this study, artificial intelligence was applied to predict residual stress and optimize machining paths for 2xxx series aluminium alloys. Bulk residual stress induced by quenching after extrusion was predicted using an ANN model based on geometry and quenching parameters, while machining-induced residual stress was predicted using a regression model with machining parameters. These stresses were incorporated into finite element simulations to efficiently predict machining-induced distortion.