Study On Temperature Field And Residual Stress Distribution For6061Aluminium Alloy During High-speed Milling Process

High-speed milling is an advanced manufacturing technology with highefficiency, high accuracy and low cost. It has been widely used in aerospace,automobile and die industry, this trend has naturally lead research focus ondeformation during milling process. Many factors influence milling deformation,there are some studies start from milling parameter and temperature. Most studieshave attributed deformation mainly to release of residual stress. This study choose6061aluminum alloy as research object, established finite element model of millingprocess, examined rationality of this model with milling temperature, milling forceand residual stress measurement experiment. Main contents of this paper aresummarized as follows:（1） Obtained force data within manufacturing milling parameter byorthogonal test, established empirical formula through linear regression. Milling forcedata can be easily estimated by this formula. Measurement of milling force hasprovided conditions for analytic calculation of milling temperature.（2） Calculated generation of milling heat and deployment between differentpart. Reasoned milling temperature field based on heat source method. Obtainedanalytic calculation of temperature field obey solid heat conduction law by simplifiedheat source and hear transfer conditions. Under the condition of knowing millingparameters and milling force, we can get the temperature of any location at any timein the milling process through this analytic model. This paper also obtained millingtemperature under dry milling condition with infrared thermal imaging technologythrough experiment.（3） Measured residual stress data of surfaces by blind hole method, thisresult can be used to examine the rationality of finite element simulation. （4） Established and calculated2-D thermal-mechanical coupling finiteelement model and3-D finite element model using ABAQUS. Identified constitutiveand fracture criterion of6061material model, established finite element model basedon this material model. Carried out2-D thermal-mechanical coupling calculation bysimplified question to plane strain problem; obtained residual stress field andtemperature field. Explore possibility of3-D simulation under real milling conditions,established3-D model without thermal coupled. Compared between experiment resultand two kinds of finite element model, verified the rationality of finite elementsimulation.