Numerical and Experimental Investigation of Residual-Stress-Induced Distortions in Cold Forged EN AW-6082 Aluminium Specimens After Targeted Milling.
1
Department of Bulk Metal Forming, Institute for Metal Forming Technology, University of Stuttgart, Germany
2
Cutting Department, Institute for Machine Tools, University of Stuttgart, Germany
3
Management, Institute for Metal Forming Technology, Univesity of Stuttgart, Germany
4
Management, Institute for Machine Tools, University of Stuttgart, Germany
These authors had equal contribution to this work
Submission date: 2026-02-09
Final revision date: 2026-04-24
Acceptance date: 2026-04-27
Online publication date: 2026-05-18
Corresponding author
Radu Andrei Matei
Department of Bulk Metal Forming, Institute for Metal Forming Technology, University of Stuttgart, Germany
Department of Bulk Metal Forming, Institute for Metal Forming Technology, University of Stuttgart, Germany
KEYWORDS
TOPICS
ABSTRACT
Near-net-shape (NNS) cold forging offers significant potential for material savings compared to processes like machining
from solid billets. However, this process introduces residual stress (RS) fields that can cause distortions during subsequent
machining. Predicting and controlling these distortions is essential for ensuring dimensional accuracy and minimising
scrap rates in industrial applications. This study investigates the distortions caused by targeted milling operations on
extruded aluminium cross-shaped specimens made from an EN AW-6082 aluminium alloy. The aim is the determination
of the predictive capabilities of machining-induced distortions from RS liberation by commercial FEM software.
Elastoplastic FEM simulations of the complete operation chain are developed using DEFORM 3D. Boolean operations
combined with RS relaxation are used to simulate the milling operations in a simplified way. The numerical results are
validated experimentally using systematic milling tests and software-aligned 3D scans of the specimens at all tested
milling depths. The results are in good agreement, with simulations showing an average discrepancy of 22% with respect
to experiments, good distortion mode prediction and the capture of observed trends in the influence of milling depth.
However, a more accurate and repeatable alignment strategy is required for a higher confidence in the predictions.
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| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
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