2024铝合金铣削加工表面残余应力仿真研究

为了研究不同的铣削参数对2024铝合金铣削过程中铣削加工表面残余应力的影响,采用有限元仿真与试验验证结合的方法,利用有限元建立2D铣削仿真模型,研究铣削过程中切削表面残余应力随切削参数的变化,并在相同的切削参数下进行铣削试验测量切削表面残余应力,采用正交试验和单因素试验对铣削参数进行优化。结果表明,有限元仿真的结果与试验的结果数据相近,验证了有限元模型的准确性,通过正交试验选出最优的铣削工艺参数为切削速度500m/min、每齿进给量0.05mm/z、铣削宽度10mm、铣削深度0.5mm;在切削2024铝合金时,在不影响生产的条件下,采用较低的切削速度,较低的进给量、铣削深度和铣削宽度,得到的表面残余应力值较小。

Simulation Study on Surface Residual Stress of 2024 Aluminum Alloy Milling

In order to study the influence of different milling parameters on the residual stress of milling surface during 2024 aluminum alloy milling,the milling parameters were optimized to control the residual stress.Using the combination of finite element simulation and experimental verification,a 2D milling simulation model was established by using finite element method.The residual stress of the cutting surface during milling was changed with the cutting parameters,and the milling test was carried out under the same cutting parameters to measure the residual stress of the cutting surface.The milling parameters were optimized by orthogonal test and single factor test.The results show that the results of the finite element simulation are similar to the experimental results,and the accuracy of the finite element model is verified.The optimal milling parameters are selected by the orthogonal test to be cutting speed 500m/min and feed per tooth 0.05mm./z,milling width 10mm,milling depth 0.5mm;when cutting 2024 aluminum alloy,using lower cutting speed,lower feed rate,milling depth and lower milling width without affecting production conditions,The obtained residual stress value of the surface layer is small.