Effect Of Tool Wear On Residual Stress In Turning Of 6061 Aluminum Alloy

As an alloy material with excellent performance,6061 aluminum alloy is widely used in all walks of life.Some industries have high requirements for the surface quality of aluminum alloy processing.As one of the indicators to measure the quality of the machined surface,the residual stress affects the fatigue strength,corrosion resistance and reliability of the part.Tool wear as an inevitable situation in the machining process,tool wear has a great impact on the surface quality of aluminum alloy machining.To this end,this paper conducts relevant research on the influence of tool wear on residual stress in aluminum alloy machining,and the main work done is as follows:(1)In order to improve the simulation accuracy of residual stress,a method for estimating the friction factor of knife chips is proposed.According to the simulation test,the cutting force,knife chip friction factor and cutting data model are fitted,and the cutting force is measured by the cutting experiment,and the friction factor of the cutting chip is obtained.The results show that the method improves the simulation accuracy of residual stress.(2)In order to further understand the causes of residual stress generation and change,the tool wear in aluminum alloy processing was observed,and its wear mechanism was analyzed.Through analysis,it is found that the main causes of tool wear are adhesive wear,diffusion wear and abrasive wear.(3)Measure the tool wear size and establish the tool wear model.In the state of tool wear,by changing the values of cutting depth,cutting speed and feed,the influence of each cutting data on the distribution of cutting force and residual stress is understood and explained.(4)According to the tool wear size,three wear types of rake face,back flank and cutting edge passivation were established,and then by changing the size of the wear size,the finite element software was used to analyze and understand the influence of various types of wear on the cutting force and residual stress distribution,and explained it.