The Study of the Effect of Pre-Existing Residual Stress in Rough Hard Turning on New Residual Stress in Dry SuperfinishHard Turning

小行星9612022 硬车削是一种有吸引力的替代传统的精密加工实践的形成，车削，淬火，磨削和超精加工，因为几个工艺步骤可以消除。 然而，由于缺乏知识以及热损伤和残余应力的风险，实现这种有吸引力的结果受到限制。 该项目的目标是了解和建模：预先存在的残余应力如何影响随后的残余应力和切屑形成，以及切削条件和进给量与切削深度之比如何影响残余应力。 这项研究将涉及数学建模和实验。 将使用重复两次的实验设计矩阵来评估3个水平的后刀面磨损、2个进给、2个切削深度、2个切削速度和2个刀尖半径的影响。 X射线衍射将被用来测量残余应力，和Tay等的实验方法。用于确定温度分布。这将通过使用有限元法的建模工作来补充，以预测基于热机械加工模型的残余应力。 该项目的成功可能会消除轴承等精密部件生产中的精磨和超精加工等冗长而昂贵的操作。 这意味着在保持质量的同时提高生产率。

9612022 Liu Hard turning is an attractive alternative to the conventional precision machining practice of forming, turning, hardening, grinding and superfinishing, because several process steps can be eliminated. However, achieving this attractive result has been limited by lack of knowledge and the risk of thermal damage and residual stresses. This project's objectives are to understand and model: how pre-existing residual stresses affect subsequent residual stresses and chip formation, and how cutting conditions and the ratio of feed to depth of cut affect residual stresses. This investigation will involve both mathematical modeling and experiment. An experimental design matrix, replicated twice, will be used to assess the effects of 3 levels of flank wear, 2 feeds, two depths of cut, 2 cutting speeds and 2 tool nose radii. X-ray diffraction will be used to measure residual stress, and the experimental method of Tay et. al. used to determine temperature distributions. This will be complemented by a modeling effort using the finite element method to predict residual stresses based on a thermal-mechanical model of machining. Success in this project potentially eliminates lengthy and costly operations like finish grinding and superfinishing, in the production of precision components like bearings. This means higher productivity while maintaining quality.