Theoretical prediction of machining-induced residual stresses in three-dimensional oblique milling processes
Theoretical prediction of machining-induced residual stresses in three-dimensional oblique milling processes
复制标题
三维斜铣削过程中加工引起的残余应力的理论预测
DOI：
10.1016/j.ijmecsci.2017.09.005
复制
发表时间：
2017-11
影响因子：
7.3
通讯作者：
Zhang Wei-Hong
中科院分区：
文献类型：
--
作者：
Wan Min;Ye Xiang-Yu;Yang Yun;Zhang Wei-Hong
残余应力不仅对已加工构件的疲劳寿命有很大影响，而且在大型构件的加工中会引起严重的变形，是一个需要深入研究的重要特性。以往的切削残余应力理论计算研究主要针对二维正交切削过程，针对三维铣削加工中残余应力的解析预测问题，提出了一种预测三维铣削加工残余应力的理论模型，通过考虑铣刀与工件之间的三维瞬时接触状态，对三维铣削过程中的残余应力进行了分析。建立了斜角切削的三维接触模型，综合考虑了剪切区的切削效应和珩磨区的犁削效应，预测了斜角切削的应力分布。基于切削机理、接触力学和J-C本构模型的基本原理，预测了剪切作用产生的瞬时加工应力，并利用滑移线理论计算了珩磨区的应力。模型中详细描述了两个区域中复杂的几何关系。为了研究热载荷对残余应力的影响，对铣削过程中的瞬态切削温度场进行了预测。采用增量热弹塑性方法预测了循环加载过程中工件的热弹塑性本构行为。提出了三维松弛法计算切削刃加载后的残余应力。理论预测值与有限元计算结果和实验结果吻合较好，验证了该模型的有效性。此外，还验证了该模型的计算效率明显高于有限元法。
Residual stress not only has great influence on the fatigue life of a machined component, but also can cause serious distortion in machining of large components, and thus, it is an important characteristic needed to be studied deeply. Previous researches on theoretical calculation of machining-induced residual stresses were mainly carried out for two-dimensional (2D) orthogonal cutting processes, and analytical prediction of residual stresses in three-dimensional (3D) milling is seldom reported.This paper presents a theoretical model to predict the machining-induced residual stresses in 3D milling processes by taking the 3D instantaneous contact status between the mill and part into consideration. A 3D contact model of oblique cutting is established to predict the stress distributions by integrating the cutting effect in shear zone with the ploughing effect in the honed zone of the cutting edge. Instantaneous machining stresses produced by shearing effects are predicted based on the basic principles of cutting mechanism, contact mechanics and J-C constitutive model; while the stresses in the honed zone are evaluated by using slip line theory. Complicated geometrical relationships in both zone are detailed in the model formulation. Instantaneous cutting temperature fields during milling process are predicted to study the influences of thermal loads on residual stresses. Incremental thermo-elasto-plastic method is adopted to predict the thermo-elasto-plastic constitutive behavior of the workpiece in elastic-plastic cyclic loading process. 3D relaxation procedures are proposed to calculate the final residual stresses after the loading process of the cutting edges. Validity of the proposed model is demonstrated by the good agreements between the theoretical predictions and the results by using finite element methods and experimental means. Furthermore, it is also verified that the computation efficiency of this model is significantly higher than that of finite element method.
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影响因子：
4.1
作者：
Lazoglu, I.;Ulutan, D.;Kaftanoglu, B.
通讯作者：
Kaftanoglu, B.
DOI：
10.1016/j.jmatprotec.2006.09.032
发表时间：
2007-03-05
影响因子：
6.3
作者：
Ulutan, D.;Alaca, B. Erdem;Lazoglu, I.
通讯作者：
Lazoglu, I.
影响因子：
6.3
作者：
Nilanjana Banerjee;Abhay Sharma
通讯作者：
Nilanjana Banerjee;Abhay Sharma
DOI：
10.1115/1.2830208
发表时间：
1997-11
期刊：
Manufacturing Science and Engineering: Volume 2
影响因子：
--
作者：
D. Waldorf;R. DeVor;S. Kapoor
通讯作者：
D. Waldorf;R. DeVor;S. Kapoor
DOI：
10.1115/1.3172958
发表时间：
1987-03
期刊：
Journal of Applied Mechanics
影响因子：
--
作者：
A. D. Hearle;K. Johnson
通讯作者：
A. D. Hearle;K. Johnson