scholarly journals Analytical Prediction of Residual Stress in the Machined Surface during Milling

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 498
Author(s):  
Caixu Yue ◽  
Xiaole Hao ◽  
Xia Ji ◽  
Xianli Liu ◽  
Steven Y. Liang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Prediction Model ◽  
Coupling Effect ◽  
Orthogonal Cutting ◽  
Analytical Prediction ◽  
Milling Force ◽  
Machined Surface ◽  
Mechanical Coupling ◽  
Geometric Relationship ◽  
Relationship Of

An analytical prediction model for residual stress during milling is established, which considers the thermal-mechanical coupling effect. Considering the effects of thermal-mechanical coupling, the residual stress distribution in the workpiece is determined by the stress loading history according to McDowell′s hybrid algorithm. Based on the analysis of the geometric relationship of orthogonal cutting, the prediction model for milling force and residual stress in the machined surface is established. The research results can provide theoretical basis for stress control during milling.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

Analytical Prediction and Experimental Investigation of Burnishing Force in Rotary Ultrasonic Roller Burnishing Titanium Alloy Ti–6Al–4V

2020 ◽  
Vol 142 (3) ◽  
Author(s):  
Jian Zhao ◽  
Zhanqiang Liu ◽  
Bing Wang ◽  
Yukui Cai ◽  
Qinghua Song
Keyword(s):  
Titanium Alloy ◽  
Prediction Model ◽  
Milling Process ◽  
Analytical Prediction ◽  
Ultrasonic Power ◽  
Machined Surface ◽  
Softening Effect ◽  
Force Prediction ◽  
Contact Width ◽  
Acoustic Softening

Abstract Ultrasonic burnishing is usually applied to make machined surface modification. The acoustic softening effect caused by ultrasonic vibration is beneficial to the machining of difficult-to-cut materials. In the present work, a burnishing force prediction model was proposed for rotary ultrasonic burnishing of titanium alloy Ti–6Al–4V, whose surface had been machined with the face milling process. Firstly, the contact between the burnishing roller and one single milling mark was analyzed with plane strain assumption based on the Boussinesq–Flamant contact problem. Then, the effect of ultrasonic softening on the yield stress of Ti–6Al–4V was investigated. The critical contact width and contact load that the burnishing roller crushed on one single milling mark were examined to confirm the feasibility of the proposed ultrasonic burnishing force prediction model. The experimental verifications were carried out at various ultrasonic powers. The burnishing forces from experiment measurements were consistent with the calculated results from the proposed model. The mean deviations between theoretical and experimental results of the ultrasonic burnishing force were 10.4%, 12.2%, and 15.2%, corresponding to the ultrasonic power at the level of 41 W, 158 W, and 354 W, respectively.

Effects of cutter path orientations on milling force, temperature, and surface integrity when ball end milling of TC17 alloy

2020 ◽  
pp. 095440542097107
Author(s):  
Xuehong Shen ◽  
Dinghua Zhang ◽  
Liang Tan
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Topography ◽  
Surface Integrity ◽  
End Milling ◽  
Layer Depth ◽  
Milling Force ◽  
Mechanical Coupling ◽  
Cutter Path ◽  
The Impact

To explore the effects of cutter path orientations on milling force, temperature, and surface integrity, end ball milling experiments of TC17 titanium alloy were accomplished derived from different cutter path orientations. The experiment results of milling force and temperature were obtained. Combining with the thermo-mechanical coupling, this paper analyzes the impact of the cutter path orientations on the surface roughness, surface topography, in-depth residual stress, microhardness distributions, and microstructure. The results indicate that the maximum milling force is 224.24 N and the temperature is 672°C under vertical downward milling path, while horizontal downward orientation provides the lowest cutting force of 81.12 N and temperature of 493°C. The surface topography of the four cutter path orientations is basin-like shape, and the minimum surface roughness of 1.128 µm is achieved under vertical upward mode. Moreover, the maximum compressive residual stress of −491.8 MPa and the maximum residual stress layer depth of 45 µm are acquired under vertical downward milling. The maximum microhardness can arrive at 390 HV0.025 under the vertical path. Additionally, the transformation of the material microstructure remains elongated, bent, and fractured. The maximum plastic deformation layer depth is 44 µm under vertical downward milling path.

scholarly journals Surface Roughness and Residual Stresses of High Speed Turning 300 M Ultrahigh Strength Steel

2014 ◽  
Vol 6 ◽  
pp. 859207 ◽  
Author(s):  
Zhang Huiping ◽  
Zhang Hongxia ◽  
Lai Yinan
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Prediction Model ◽  
Feed Rate ◽  
High Speed ◽  
Stress Test ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Factors Affecting

Firstly, a single factor test of the surface roughness about tuning 300 M steel is done. According to the test results, it is direct to find the sequence of various factors affecting the surface roughness. Secondly, the orthogonal cutting experiment is carried out from which the primary and secondary influence factors affecting surface roughness are obtained: feed rate and corner radius are the main factors affecting surface roughness. The more the feed rate, the greater the surface roughness. In a certain cutting speed rang, the surface roughness is smaller. The influence of depth of cut to the surface roughness is small. Thirdly, according to the results of the orthogonal experiment, the prediction model of surface roughness is established by using regressing analysis method. Using MatLab software, the prediction mode is optimized and the significance test of the optimized model is done. It showed that the prediction model matched the experiment results. Finally, the surface residual stress test of turning 300 M steel is done and the residual stress of the surface and along the depth direction is measured.

Effects of Tool Geometrical Parameters on the Chip Formation and Cutting Force in Orthogonal Cutting

2004 ◽  
Vol 471-472 ◽  
pp. 16-20 ◽  
Author(s):  
Gang Fang ◽  
P. Zeng
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Coupling Effect ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Geometrical Parameters ◽  
Actual Process ◽  
Mechanical Coupling ◽  
Chip Separation

The tool plays an important role in cutting process. The aim of this paper is to investigate the effect of tool geometrical parameters on the chip formation and cutting force with orthogonal cutting models. The large deformation Rigid-visco-plastic FEM program DEFORM-2DTM is used, and thermo-mechanical coupling effect are considered. The chip separation from workpiece is implemented by remeshing. Contrary to traditional cutting simulation, the workpiece is moved and the tool is fixed, which is consistent with actual process. The effects of tool rake angle on the chip geometry and cutting force are analyzed. The simulated cutting forces are compared with results in other references. The research results are a help to cutting process study and cutting tool design.

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