Milling Force Modeling Of Alloy 2219 Arc Plates And Its Influence On Residual Stress

The container wall plate of the Long-march series carrier rocket is typical large arc plate and the milling wall grid is a key cutting process to determine the geometry precision and manufacturing efficiency.The material removal rate of arc plate parts is obviously different from that of flat plate and the influences of cutting parameters,tool parameters and path on milling force and residual stress of arc plate are not clear.It has important theoretical significance and practical value to establish a mechanical model with high universality and analyze the influence of milling force on the residual stress of arc plate considering the cutting performance of the work-piece material,the geometric feature information of the work-piece/cutter,the technological parameters and the tool path,etc.In this paper,aluminum alloy 2219 was taken as the research object.The dynamic compressive mechanical properties of aluminum alloy 2219 were studied by using separate Hopkinson press and the test of quasi-static compressive mechanical properties were performed by the electronic universal testing machine.The mechanical behavior was obtained under a wide range of temperature and strain rates.The Johnson-Cook model was proposed to predict the flow stress of materials in experiments.The model takes into account the temperature effect and strain rate effect and provides the basis for the aluminum alloy 2219 cutting simulation.According to the material failure criterion,knife-chip friction model,grid division,Johnson-Cook model and other simulation key technologies,the 2d milling simulation of the plate and the arc plate were carried out by using finite element software ABAQUS.The differences in the forming process of the chip and the variation of the stress and strain of the work-piece were analyzed.The instantaneous prediction model of 2219 aluminum alloy arc plate was established based on the idea of differential and the geometrical model of arc edge milling cutter and arc plate.The experience model of the milling force of 2219 aluminum alloy arc plate was established through orthogonal experiment.The influences of different technological parameters on the milling force change were analyzed.The residual stresses before and after milling were measured by X-ray diffraction.The variation of residual stress under different milling forces was analyzed by calculating the change in residual stress before and after milling.The experimental results show that the variation of residual stress along the feed direction is less consistent with the milling force and the consistency between the residual stress and the milling force is good when the direction is perpendicular to the feed direction.The residual stress prediction model of milling parameters was obtained by SPSS software.