Finite Element Simulation And Experiment Of Residual Stress In Machined Surface

The machined surface residual stress easily lead to deformation and surface crack, impact of theworkpiece surface quality, thereby affect the mechanical properties and the fatigue life of theworkpiece. Therefore, accurately predicted the machined surface residual stress is of greatsignificance and practical value. The dissertation is based on the research of the generationmechanism and prediction of surface residual stresses for turning and grinding, carried out modelingand calculation of surface residual stresses for turning and grinding by using the finite elementmethod, compared and analyzed the numerical calculation results combined with the experimentaldetection of residual stress for train vehicle axle machining.Through fracture damage and failure technology, and explicit thermal-mechanical stress couplingalgorithm, the ribbon chip of2D orthogonal cutting process for45steel was simulated, the formationprocess of the ribbon chip and the machined surface residual stress were studied, the effects of cuttingparameters and tool geometry parameters for the size and distribution of surface residual stress wereanalyzed.uniform thermal flux and grinding force were applied on the contact length by using aintermittent and jumping movable load, adopted thermal elastic-plastic finite element method,3Dgrinding process of50steel was simulated, calculated grinding temperature and surface residual stressunder different cutting parameters, and analyzed the effects of cutting parameters for them.Combined with practical engineering application, conducted the processing experiments with50steel as an object of train vehicle axle material, measured the machined workpiece surface residualstress, analyzed the order of importance about the effects of process parameters for residual stress. Atlast, the FEM simulation results were compared with experiments show the validity of the FEAmodel.In this paper, turning and grinding residual stress FEM model were established, calculated theresidual stress under different cutting conditions, carried out the relevant process experiment.Compared numerical simulation results with experimental results shows that the model can reflect thecharacteristics of residual stress in machining, it is in favor of further study the generation mechanismof residual stress, providing a model and algorithm for the research and application of processoptimization of the part.