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A novel analytical modeling for prediction of residual stress induced by thermal-mechanical load during orthogonal machining
The International Journal of Advanced Manufacturing Technology ( IF 3.4 ) Pub Date : 2020-07-04 , DOI: 10.1007/s00170-020-05594-2
Chengyan Zhang , Lixin Wang , Wuzhou Meng , Xiaoli Zu , Zijun Zhang

Residual stress on the surface and subsurface has a great influence on the distortion and fatigue life. Rapid and accurate prediction of residual stress is important for the optimization of the machining process in intelligent manufacturing. A novel analytical model is proposed based on the equivalent stress method in this paper. The nonlinear flow characteristics of the work-piece material in the tool-work-piece contact surface and thermal-mechanical coupling effect are fully considered. A new cutting force prediction model was established and the relative errors are within 12%, which verifies the accuracy and the effectiveness of the model for further application to residual stress prediction. The thermal-mechanical conditions of the primary shear plane and machined surface are revealed based on the equivalent stress method. Then, internal stress of work-piece is caused by mechanical load and thermal load obtained on account of linear elasticity theory and heat-elastic-plastic mechanics theory. The predicted residual stress profiles have a high degree of consistency with measurement results of orthogonal turning of 20Cr2Ni4A alloy steel. Prediction accuracy of surface residual stresses was 11.3%, 12.2%, and 12.7% for the condition of v = 24 m/min, ap = 0.1 mm; v = 36 m/min, ap = 0.2 mm; v = 48 m/min, ap = 0.3 mm respectively. The predicted results of the maximum compressive stresses and DMCS are also acceptable. Ultimately, the residual stress profiles obtained from proposed model were reliable. The proposed model has high computational efficiency and provides a new idea for the analytical prediction of residual stress. And the proposed model can be used for further residual stress analysis and prediction of 3D cutting process.



中文翻译:

预测正交加工过程中热机械载荷引起的残余应力的新型解析模型

表面和次表面上的残余应力对变形和疲劳寿命有很大影响。快速而准确地预测残余应力对于优化智能制造中的加工过程非常重要。提出了一种基于等效应力法的新型解析模型。充分考虑了工件材料在工具-工件接触表面中的非线性流动特性以及热力耦合效应。建立了新的切削力预测模型,相对误差在12%以内,验证了该模型的准确性和有效性,可进一步应用于残余应力预测。基于等效应力法揭示了主剪切平面和机加工表面的热机械条件。然后,工件的内部应力是由线性弹性理论和热弹塑性力学理论获得的机械载荷和热载荷引起的。预测的残余应力分布与20Cr2Ni4A合金钢的正交车削测量结果具有高度的一致性。在以下条件下,表面残余应力的预测精度分别为11.3%,12.2%和12.7%。v = 24米/分钟,一个p = 0.1毫米; v = 36米/分钟,一个p = 0.2毫米; v = 48米/分钟,一个p = 0.3分别毫米。最大压缩应力和DMCS的预测结果也是可以接受的。最终,从提出的模型获得的残余应力分布是可靠的。该模型计算效率高,为残余应力的解析预测提供了新思路。所提出的模型可用于进一步的残余应力分析和3D切削过程的预测。

更新日期:2020-07-05
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