Abstract

In addition to having significant effects on the service life of machined parts, residual stress can cause large deformations during machining of thin-walled parts in aerospace field. The residual stress in machined part surface layer is induced by mechanical and thermal stress in the machining process of parts. Therefore, it is essential to accurately predict the generated residual stress due to the machining process. To address this issue, an improved prediction model of the residual stress for orthogonal cutting process based on analytical method is presented by taking the mechanical and thermal stress into consideration. Oxley’s cutting force model and Waldorf’s plowing force model are used to calculate the chip formation force and plowing force based on the contact mechanics, Johnson-Cook constitutive model, and slip line theory. The cutting temperature is predicted according to our previous work based on the Huang-Liang model and the Komanduri-Hou model. The final residual stress is predicted by calculating the loading and relaxation of mechanical and thermal stress. The presented prediction method of residual stress is validated by orthogonal cutting of a Ti6Al4V pipe. It is found that the prediction values of the presented model show a good agreement with the experimental results, which indicates that the presented model can be adopted to predict the residual stress of Ti6Al4V during orthogonal cutting.

中文翻译：

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Ti6Al4V正交切削中加工引起的残余应力的预测

摘要

除了对机加工零件的使用寿命有重大影响外，残余应力还会在航空航天领域对薄壁零件进行加工时引起较大的变形。零件加工过程中的机械应力和热应力会引起加工零件表面层中的残余应力。因此，必须准确地预测由于加工过程而产生的残余应力。针对这一问题，提出了一种基于解析法的机械切削和热应力改进的正交切削残余应力预测模型。基于接触力学，Johnson-Cook本构模型和滑移线理论，使用Oxley的切削力模型和Waldorf的耕犁模型来计算切屑形成力和耕犁力。根据我们先前基于Huang-Liang模型和Komanduri-Hou模型的工作来预测切削温度。通过计算机械应力和热应力的加载和松弛来预测最终的残余应力。通过正交切削Ti6Al4V管验证了本文提出的残余应力预测方法。结果表明，该模型的预测值与实验结果吻合良好，表明该模型可用于预测Ti6Al4V在正交切削过程中的残余应力。通过正交切削Ti6Al4V管验证了本文提出的残余应力预测方法。结果表明，该模型的预测值与实验结果吻合良好，表明该模型可用于预测Ti6Al4V在正交切削过程中的残余应力。通过正交切削Ti6Al4V管验证了本文提出的残余应力预测方法。结果表明，该模型的预测值与实验结果吻合良好，表明该模型可用于预测Ti6Al4V在正交切削过程中的残余应力。