Research On Residual Stress Of The Water Chamber Head Cutting Tool And Finite Element Analysis

In the study of water chamber head machining technology process, we foundthat the welding tool’s breakage was serious in the process of removing most ofthe material, resulting low production efficiency. The study found that cuttingtool residual stress was one of the main causes of the cutting tool prematurefailure in the cutting process. For the heavy-duty carbide welding tool, the sourceof the residual stress mainly have two aspects, which are produced by the processof welding and produced by the process of cutting. In this paper, we made afurther research on the source of two kinds of residual stress.First of all，from the materials properties of several parts in the tools(YT5inserts, solder and steel45cutting tool body) and welding process of heavy-dutycarbide welding tool, we began to explore the main cause of welding residualstress and made the welding experiments, and used the finite element softwaresimulation to analyze the welding process. We analyzed the distribution ofwelding residual stress in the tool according to the results of simulation. What’smore, based on this results, we determined the test point in the test of weldingresidual stress.Second, we analyzed the cutting temperature field and stress field in thecutting process. Through the theory combined with finite element simulation, weanalyzed it was significant effects on cutting tool residual stress between cuttingtemperature and cutting stress, and used the cutting experiment to validate theconclusion. At the same time we carried out wear experiment to determine thecenter location of the crater wear, and analyzed the relationship between residualstress and cutting crater wear.Then, based on analysis the basic principle of nano indentation method, we optimized the best theoretical model to carry out nano indentation testingexperiment. We tested the residual stress of weld insert and corresponding cuttingarea, and analyzed test results. Before the test experiment, we used scanningelectron microscopy to choose good welding test-piece which has no crack andthe element diffusion between each section in good condition.At last, under the research of welding residual stress and cutting residualstress, we tried to adjust and control two kinds of residual stress. In order toreduce welding residual stress, we used vibratory stress relief and ultrasonicpeening to conduct welding tool, and got validation experiment to processed tool.In order to reduce cutting residual stress, we used the finite element simulation tooptimist cutting parameters, and designed new type of three-dimensional groovetype tool according to the heavy cutting requirement.