切削加工表面残余应力研究综述

随着高性能制造技术的发展,对零部件的加工质量提出了更高的要求,已加工表面残余应力作为表面加工质量的重要指标,对机器零部件的使用性能有极大的影响。本文介绍已加工表面残余应力对零件使用性能的影响,论述了切削力和切削温度的研究现状及影响因素;综述了已加工表面残余应力的发展现状并阐述残余应力产生机理及其对表面机械性能的影响;总结了影响加工表面残余应力的因素,从而控制已加工表面残余应力,提高机械加工表面质量。     

椭圆振动切削的表面残余应力有限元模拟研究

基于ALE(Arbitrary Lagrange-Euler)网格划分方法建立了椭圆振动切削有限元仿真模型,模拟了椭圆振动切削过程中切削力的变化规律,并将模拟获得的切削力平均值与相同工艺参数下Kim等人[1]所做的超声椭圆振动切削V型槽实验获得的切削力平均值比较,验证了有限元模型的正确性。利用建立的二维有限元模型模拟了椭圆振动切削和普通切削表面残余应力的分布情况,对比结果表明,采用椭圆振动切削的工件已加工表面在一定深度内形成了分布均匀的表面残余压应力,而普通切削情况下工件已加工表面并没有形成有效的残余压应力,从而预测了椭圆振动切削不仅能够降低切削力、延长刀具使用寿命,还对提高工件表面完整性、增强疲劳寿命和抗腐蚀能力等具有显著的作用。     

钛合金切削加工表面残余应力有限元仿真

采用Johnson- Cook失效准则,建立了钛合金的二维正交切削热-机械应力耦合有限元仿真模型,分析计算了不同切削条件下已加工表面残余应力的分布规律.结果表明:已加工表面层残余应力为拉应力,沿着深度方向由拉应力逐渐过渡到压应力.表面残余应力随着切削速度的增大而增大,在一定的前角变化范围内,随着刀具前角的增大,表面残余拉应力先增大后减小,而随着刀具后角的增大却减小.各加工参数对残余应力层的厚度影响都很小.     

钛合金切削加工表面残余应力有限元仿真

采用JobnSOn—Cook失效准则,建立了钛合金的二维正交切削热一机械应力耦合有限元仿真模型,分析计算了不同切削条件下已加工表面残余应力的分布规律。结果表明：已加工表面层残余应力为拉应力,沿着深度方向由拉应力逐渐过渡到压应力。表面残余应力随着切削速度的增大而增大,在一定的前角变化范围内,随着刀具前角的增大,表面残余拉应力先增大后减小,而随着刀具后角的增大却减小。各加工参数对残余应力层的厚度影响都很小。     

切削加工残余应力的有限元分析

在切削加工中,为了提高已加工工件的表面质量,需要研究切削速度和进给量对已加工工件残余应力的影响规律。根据弹塑性有限元理论,利用有限元软件建立了切削模型,得到了不同切削速度和进给量下已加工工件的残余应力。结果表明,增大切削速度有利于增大深层压应力,同时也会增大表面拉应力;增大进给量有利于增大深层压应力,但对表面拉应力的影响无明显规律。     

切削速度对工件表面残余应力的有限元模拟

针对正交切削加工建立了平面应变模型;利用通用的有限元软件,对所建立的模型进行模拟,得到了不同切削速度下工件表面残余应力模拟结果,并对这些结果进行了比较分析,得出切削速度对工件表面不同方向的残余应力的基本影响规律。     

不锈钢切削残余应力实验研究

已加工表面残余应力是衡量零件加工表面质量的一个重要指标。针对目前缺乏对不锈钢切削残余应力研究的现状,通过实验研究切削冷却条件和切削参数对不锈钢加工残余应力的影响,并应用热力耦合理论进行分析。实验结果表明,不锈钢因切削产生的加工残余应力表现为拉应力,切削冷却条件和切削参数均对残余应力大小有影响,作用效果与切削液的冷却能力、渗透力及高温工作能力有关。     

刀刃半径对不锈钢切削表面残余应力影响的模拟

建立了平面应变有限元模型，采用更新的Lagrange方法模拟了奥氏体不锈钢AISI316L的正交切削过程；研究了刀刃圆弧半径对已加工表面残余应力的影响，发现随着半径的增大，残余拉应力和压应力的数值都增大，压应力层厚度也增大，但是拉应力层厚度不变。将模拟结果与实验结果进行对比，发现二者是吻合的，从而验证了有限元模拟的可用性。     

GH4169镍基合金已加工表面残余应力的仿真分析

针对薄壁GH4169镍基高温合金切削加工后表面残余应力大导致表面质量差的问题,研究了切削参数和刀具几何角度对已加工表面残余应力大小及其沿深度方向变化分布的影响规律,通过最小二乘法对所得结果进行了数值分析,侧重筛选对残余应力影响较大的因素,进而采用正交实验法和极差分析法分析刀具前角、后角对已加工表面残余应力的影响规律.结...     

航空不锈钢铣削表面残余应力试验

为了研究耐热不锈钢1Cr11Ni2W2Mo V切削用量对加工表面残余应力的影响规律,采用正交试验法进行铣削试验。建立了切削用量与加工表面残余应力之间的经验公式,并分析了铣削用量对加工表面残余应力的影响规律。结果表明,加工表面的进给方向(X方向)和垂直进给方向(Y方向)都会产生残余拉应力;在选用的铣削参数范围内,每齿进给量对X方向残余应力的影响最为显著,铣削速度对Y方向残余应力的影响最显著;X方向和Y方向表面残余应力都随铣削速度和进给量的增加而增加,随切削深度的增加而减小。     

Modelling the effects of cutting parameters on residual stresses in hard turning of AISI H11 tool steel

In the present study, an attempt has been made to model the effect of cutting parameters (cutting speed, feed, depth of cut and nose radius) on residual stresses in hard turning of AISI H11 tool steel using ceramic tools. The machining experiments were conducted based on response surface methodology and using the Box–Behnken design of experiments. Residual stresses were determined using the X-ray diffraction technique, and the experimental results were investigated using analysis of variance. The results indicated that the feed and depth of cut are the main influencing factor on residual stresses whereas cutting speed and nose radius are having mild impact on residual stresses. The results show that it is possible to produce tailor-made residual stress levels by controlling the tool geometry and cutting parameters. The aim of this paper is to introduce an original approach for the prediction of residual stresses.     

Optimization of cutting conditions for minimum residual stress,cutting force and surface roughness in end milling of S50C medium carbon steel

Residual stresses are usually imposed on a machined component due to thermal and mechanical loading. Tensile residual stresses are detrimental as it could shorten the fatigue life of the component; meanwhile, compressive residual stresses are beneficial as it could prolong the fatigue life. Thermal and mechanical loading significantly affect the behavior of residual stress. Therefore, this research focused on the effects of lubricant and milling mode during end milling of S50C medium carbon steel. Numerical factors, namely, spindle speed, feed rate and depth of cut and categorical factors, namely, lubrication and milling mode is optimized using D-optimal experimentation. Mathematical model is developed for the prediction of residual stress, cutting force and surface roughness based on response surface methodology (RSM). Results show that minimum residual stress and cutting force can be achieved during up milling, by adopting the MQL-SiO₂ nanolubrication system. Meanwhile, during down milling minimum residual stress and cutting force can be achieved with flood cutting. Moreover, minimum surface roughness can be attained during flood cutting in both up and down milling. The response surface plots indicate that the effect of spindle speed and feed rate is less significant at low depth of cut but this effect significantly increases the residual stress, cutting force and surface roughness as the depth of cut increases.     

Application of quenching to create highly triaxial residual stresses in type 316H stainless steels

It has been proposed that highly triaxial residual stress fields may be sufficient to promote creep damage in thermally aged components, even in the absence of in-service loads. To test this proposal, it is necessary to create test specimens containing highly triaxial residual stress fields over a significant volume of the specimen. This paper presents results from an experimental and numerical study on the generation of triaxial residual stresses in stainless steel test specimens. Spray water quenching was used to generate residual stress fields in solid cylinders and spheres made from type 316H stainless steel. A series of finite element simulations and measurements were carried out to determine how process conditions and specimen dimensions influenced the resulting residual stress distributions. The results showed that highly compressive residual stresses occurred around the surfaces of the cylinders and spheres and tensile residual stresses occurred near the centre. Surface residual stresses were measured using the incremental centre hole-drilling technique, while internal residual stresses were measured using neutron diffraction. Overall there was good agreement between the predicted and measured residual stresses. The level of triaxiality was found to be very sensitive to the heat transfer coefficient, and could be controlled by adjusting the cooling conditions and changing the dimensions of the steel samples. This differed from other processes, such as welding and shot-peening, where the magnitudes and distributions of residual stresses are ill-defined and the volume of material subjected to a triaxial residual stress state is relatively small.     

MACHINING RESIDUAL STRESSES IN AISI 316L STEEL AND THEIR CORRELATION WITH THE CUTTING PARAMETERS

It is well known that machining results in residual stresses in the workpiece. These stresses correlate very closely with the cutting tool geometrical parameters as well as with the machining regime. This paper studies the residual stress induced in turning of AISI 316L steel. Particular attention is paid to the influence of the cutting parameters, such as the cutting speed, feed and depth of cut. In the experiments, the residual stresses have been measured using the X-ray diffraction technique (at the surface of the workpiece and in depth). The effects of cutting conditions on residual stresses are analyzed in association with the experimentally determined cutting forces. The orthogonal components of the cutting force were measured using a piezoelectric dynamometer.     

Wear mechanisms and residual stresses in alumina-based laminated cutting tools

The outstanding performances of the Al₂O₃ cutting tools in terms of potential cutting speed can lead to substantial economies in the machining of metallic materials.Nevertheless, their widespread use is limited by some drawbacks such as the tendency to edge chipping and to the propagation of microcracks, which can lead to premature failures.These shortcomings are due to the intrinsic low toughness of the ceramic material, which is in turn related to its characteristics non-metallic bonds.A well-recognised method of increasing the toughness of brittle materials is the introduction of surface compressive stresses, which can be obtained through a suitable lamination geometry of the tools as consequence of the different coefficients of thermal expansion (CTE) of the constituent layers.The performances of an alumina/zirconia laminated cutting tool used for machining steel have been investigated and compared to those of a non-laminated commercial alumina/zirconia cutting tool. The different wear mechanisms are explained on the basis of the different microstructures and chemical compositions. We have shown that residual compressive stresses, measured by Piezo-Spectroscopy, are effective in avoiding the microchipping on the flank zone but cannot avoid larger fractures caused by the residual porosity.     

A comparison of residual stresses in built-up steel beams using hole-drilling method

Residual stresses have a significant effect on the stability resistance of metal building systems. An experimental program was conducted to measure these stresses in built-up steel beams using incremental hole-drilling method. The experimental results reveal that the predicted residual stress type of pattern for built-up I-sections with fillet welds on one side of the web is not the same as the pattern of residual stresses in built-up I-sections with fillet welds on both sides of the web. This paper was recommended for publication in revised form by Associate Editor Youngseog Lee Mohammed Al-Nawafleh received his B.S. and M.S degrees in Mechanical Engineering from Leningrad Institute of Textile and Light Industry, in 1989. He then received his Ph.D. degree from Sankt-Petersburg State University of Technology and Design, Russia in 1993. Dr. Nawafleh (1997–2005) was a Professor at the Department of Mechanical Engineering at Al-Balqa’ Applied University in Jordan. From 2005 to 2008 he was a Professor at the Department of Mechanical Engineering at Tafila Technical University, and currently he is a Professor at the Department of Civil Engineering at Al-Hussein Bin Talal University, Jordan.     

高温合金GH169拉削残余应力研究

分析拉削GH 169合金时 ,速度、齿升量、拉刀前角对拉削表面残余应力的影响。试验结果表明 ,沿拉削速度方向的表面残余应力为拉应力 ,最大残余应力在表面层下。     

Transient and residual thermal stresses in quenched cylindrical bodies

To predict residual and thermal stresses which occur during water quenching of solid cylindrical rod and ring cross-sectioned steel tubes, a finite element technique has been used. The variations of residual stresses on different surfaces and cross-sections, e.g. in the radial, axial and tangential directions have been examined, and the effect of internal diameter of tubes on residual stress was investigated. The results show that the residual stresses act as a compressive force along the cooling surface and then by moving away from the surface begin to decrease and reverse their sign, near the centre of the cylinder are subjected to tensile stresses. Because of the reversal of the sign of stress, the effective stress goes to a minimum at some distance from the frontal surface and this may be vital since lower plastic deformation may cause cracking failure. As in solid cylinder, in cylindrical tubes also, the frontal and the upper cooling surface has significant effect on the stress distribution. From the comparison of the residual stress distributions of solid cylinder and cylindrical tubes and using their individual stress maps it was seen that they vary considerably along different cooling surfaces, especially at the frontal surface.     

Structural analysis and intergranular corrosion tests of AISI 316L steel

Pure AISI 316L steel is investigated after solution heat treatment (1050 °C/H₂O) and structural sensitization (650 °C). Two quite different intergranular corrosion tests are used to determine the degree of structural sensitization due to the precipitation of secondary phases along the grain boundaries (mainly the M₂₃C₆ and σ‐phase): the oxalic acid etch test and the electrochemical potentio‐kinetic reactivation test. Generally, the dissolution of chromium‐rich carbides (M₂₃C₆) is provoked by oxalic acid etch tests, whereas the chromium‐depleted zones, in the vicinity of chromium‐rich carbides (M₂₃C₆), are attacked by electrochemical potentio‐kinetic reactivation tests. Both intergranular corrosion tests are used to determine the maximum degree of structural sensitization. Thus structural analysis by carbon replicas reveals the Laves phase, and both the M₂₃C₆ and (Cr,Mo)_x(Fe,Ni)_y phases. The results of intergranular corrosion tests are related to the findings of the structural analysis.     

Direct laser cladding of SiC dispersed AISI 316L stainless steel

The present study concerns development of SiC dispersed (5 and 20 wt%) AISI 316L stainless steel metal-matrix composites by direct laser cladding with a high power diode laser and evaluation of its mechanical properties (microhardness and wear resistance). A defect free and homogeneous composite layer is formed under optimum processing condition. The microstructure consists of partially dissociated SiC, Cr₃C₂ and Fe₂Si in grain refined stainless steel matrix. The microhardness of the clad layer increases to a maximum of 340 VHN (for 5% SiC dispersed) and 800 VHN (for 20% SiC dispersed) as compared to 150 VHN of commercially available AISI 316L stainless steel. Direct laser clad SiC dispersed AISI 316L stainless steel has shown an improved wear resistance against diamond surface with a maximum improvement in 20% SiC dispersed AISI 316L stainless steel. The mechanism of wear was predominantly abrasive in nature.