Simulation Analysis Of Residual Stress Distribution And Process Optimization Of 65Mn Circular Saw Blade Matrix Roll Tensioning

65Mn circular saw blades are widely used in cutting processes such as wood,stone,nonferrous metals,and building profiles.With the promotion and development of green manufacturing concept in the cutting industry,reducing the thickness of circular saw blades to reduce material loss and cutting energy consumption has become a key research direction for cutting tool manufacturing enterprises.However,the cutting stability of circular saw blades becomes worse when the thickness of circular saw blades matrix is reduced.Reducing the thickness of the circular saw blade matrix while ensuring the stability of the cutting process has become a technical problem faced by the cutting tool manufacturing industry.By improving the residual stress distribution of the circular saw blade matrix,the stiffness of the circular saw blade matrix can be enhanced,and the stability of the circular saw blade cutting process can be significantly improved.At present,the main way to control the internal residual stress of the circular saw blade matrix is roll tensioning.The roll tensioning generates plastic deformation bands at specific positions on the circular saw blade matrix through rolling,thereby improving the distribution of residual stress inside the circular saw blade matrix and improving the stability of the cutting process of the circular saw blade.However,the selection of roll tensioning parameters mostly depends on the accumulated process experience of enterprises and the preferences of operators,lacking theoretical basis and method specifications,which greatly affects the quality of circular saw blade matrix.This article aims to conduct research on the 65 Mn material circular saw blade matrix,exploring the generation mechanism and distribution law of residual stress in rolling tension from three levels: roll tensioning residual stress testing experiment,theoretical calculation,and finite element simulation.And on this basis,the optimization test of roll tensioning process was carried out to form an effective optimization method for optimizing the roll tensioning parameters.Firstly,the material parameter test and roll tensioning residual stress testing experiments were conducted on the 65 Mn circular saw blade matrix with a diameter of1160 mm.By analyzing the changes in stress distribution of the circular saw blade matrix before and after rolling,the distribution law of roll tensioning residual stress was obtained:the radial residual stress presents a "low-high-low" distribution along the radius direction;the tangential residual stress presents a "positive outside and negative inside" distribution along the radius direction.Secondly,based on the "three ring theory" and the concept of thin film force in the stress analysis of convex formwork,mathematical models of roll tensioning residual stress were established respectively.A theoretical calculation of residual stress during roll tensioning was conducted on the 65 Mn circular saw blade substrate with a diameter of1160 mm.The distribution law of the calculated roll tensioning residual stress was summarized,and the accuracy of the mathematical model was verified.Thirdly,a case simulation study was conducted on a 65 Mn circular saw blade matrix with a diameter of 1160 mm which based on ABAQUS,verifying the correctness of the simulation model and modeling method.Summarized the distribution law of roll tensioning residual stress along the thickness direction of the circular saw blade matrix,and the results show that the material flow caused by roll tensioning goes through the entire thickness direction of the circular saw blade matrix,not limited to the indentation surface.Finally,taking the axial stiffness of the circular saw blade matrix as the optimization objective,the orthogonal optimization test were conducted on the roll tensioning process parameters of the 65 Mn circular saw blade matrix with a diameter of 1160 mm,and the optimization method for rolling and tensioning process parameters was studied.The axial stiffness of the circular saw blade matrix treated by the optimized process parameter scheme is 16.8% higher than the example scheme determined according to the production experience of the enterprise,which proving the effectiveness of the roll tensioning process parameter optimization method.At the same time,the finite element simulation of roll tensioning residual stress was carried out on the optimized process parameters,and the influence law of roll tensioning residual stress distribution on the axial stiffness of circular saw blade matrix was obtained.