A Simplified Analytical Model for Strip Buckling in the Pressure-Assisted Milling Process

Area of Science:

• Mechanical Engineering
• Solid Mechanics
• Materials Science

Background:

• Thin-walled structures are susceptible to buckling under axial loading, a critical failure mode in manufacturing processes like milling.
• Conventional bifurcation buckling theory often fails to explain buckling phenomena in complex scenarios, such as those involving lateral pressure restraint.
• Understanding and preventing buckling is crucial for ensuring structural integrity and process efficiency in industries like aerospace and automotive.

Purpose of the Study:

• To develop a simplified analytical model for thin-walled strips subjected to axial force and uniform lateral pressure.
• To investigate the buckling mechanisms and post-buckling responses under dead load and follower load conditions.
• To establish theoretical foundations for buckling prevention strategies in thin-walled components during milling.

Main Methods:

• A simplified model representing the strip as two rigid columns connected by a rotation spring was employed.
• The energy method was utilized to derive analytical solutions for post-buckling responses.
• Two loading cases (dead load and follower load) and the effect of initial geometric imperfections were analyzed.
• Finite element simulations were used to validate the analytical results.

Main Results:

• The model established minimum buckling force, Maxwell force, and stability conditions for both loading cases.
• Increased uniform lateral pressure was found to enhance the minimum buckling force, reducing the likelihood of buckling.
• Dead loads were more effective than follower loads in suppressing buckling for equivalent pressure levels.
• A linear relationship was identified between initial geometric imperfection amplitude and the critical restraining pressure required to prevent buckling.

Conclusions:

• The developed analytical model successfully elucidates the buckling mechanism of thin-walled strips under lateral pressure restraint, extending beyond conventional theories.
• The findings provide a theoretical basis for designing effective buckling prevention strategies in the milling of thin-walled structures.
• The research offers valuable insights for optimizing manufacturing processes in the aerospace and automotive industries.