Study On Hybrid Approach Of Residual Stress In Orthogonal Cutting

With the more and more development and application of high-performance manufacturing in aerospace and energy industries,universities and enterprises have gradually paid more and more attention to the impact of machining on the service performance of mechanical parts.Processing after the formation of the residual stress on the geometrical shape and dimension precision of mechanical parts,such as fatigue and corrosion resistant performance has a farreaching influence,its main study the formation mechanism of the difficulty is that it is very complex,and by the method of experimental test time-consuming,laborious residual stress is difficult to establish a fast accurate prediction model and has some limitations.In addition,the modeling of residual stress mainly focuses on steady state machining,and the prediction model of residual stress for dynamic machining process is seldom reported.Aiming at the above difficulties,this paper focuses on the modeling of residual stress in right-angle cutting,and proposes a new experiment-numerical hybrid modeling method for residual stress in orthogonal cutting based on the formation mechanism of residual stress.The specific research contents are as follows:(1)On the basis of the mechanism of the formation of residual stress using Deform aluminum alloy orthogonal cutting finite element model is set up,carry out a large number of simulation experiments,through the simulation results of cutting stress field and temperature field analysis of the cutting force affecting the formation of residual stress in thermal load,summed up the effect the machining residual stress of thermal load distribution in the PSZ and the TSZ,determines the corresponding to the force of cutting area heat load distribution form.(2)An analytical modeling method for quantifying the medium effective thermal load in orthogonal cutting is proposed for the specific distribution of the force and heat load.The key parameters such as cutting force,chip thickness,friction coefficient and effective contact length of flank angle to workpiece were obtained by carrying out orthogonal cutting experiments to provide data basis for quantifying equivalent load.(3)The prediction model of residual stress of orthogonal cutting considering the PSZ and TSZ is established,and the hybrid modeling method of experiment method and finite element method is adopted to load the moving equivalent load onto the contact surface of shear zone and cutting tool workpiece,and the material removal is realized by combining the life-death unit technology.Finally,the model is used to analyze the influence of different cutting parameters and tool's ranke angle on residual stress.(4)Dynamic cutting residual stress prediction model is established,and set the tool feed direction active vibration cutting experiment platform,including dynamic cutting depth,dynamic cutting thickness,the dynamic cutting force and other key parameters measuring module,used to get the key parameters in order to quantify the equivalent load,the residual stress prediction and experimental test and verify the effectiveness of the hybrid model under the condition of dynamic orthogonal cutting,and illustrate the influence of dynamic effect on residual stress state.