Finite element method study on the influence of initial stress on machining process

Machining-induced residual stress has significant influence on the performance of the parts. Extensive studies about machining-induced residual stress concerning many factors have been carried out but few focused on the role of initial stress distribution in cutting process. In this study, a finite element method study on the influence of initial stress on machining process is carried out. A combined method to obtain the parameters in Johnson–Cook constitutive model was introduced and verified with face milling experiments and finite element method simulations. And with this carefully established finite element method model, the influence of the value and distribution range of initial stress on cutting process was studied. The results show that the initial tensile stress makes the cutting stress distribution within the workpiece become more tensile and diminishes the cutting forces and tool tip temperature, while initial compressive stress has opposite effects. The value and distribution range of initial stress determines the strength of this influence. On the other hand, the machining process also results in the partial release of initial stress in the bulk material.

[1]  Ekkard Brinksmeier,et al.  Prediction of Shape Deviations in Face Milling of Steel , 2013 .

[2]  Y. Matsumoto,et al.  The Effect of Hardness on Residual Stresses in Orthogonal Machining of AISI 4340 Steel , 1990 .

[3]  Bang Yan Ye,et al.  Investigation into Influence of Cutting Fluid and Liquid Nitrogen on Machined Surface Residual Stress , 2012 .

[4]  D. Umbrello,et al.  Experimental and numerical modelling of the residual stresses induced in orthogonal cutting of AISI 316L steel , 2006 .

[5]  P. Manach,et al.  Material parameters identification: Gradient-based, genetic and hybrid optimization algorithms , 2008 .

[6]  Richard E. DeVor,et al.  Machining-Induced Residual Stress: Experimentation and Modeling , 2000 .

[7]  D. Amodio,et al.  Material characterization at high strain rate by Hopkinson bar tests and finite element optimization , 2008 .

[8]  Zhijun Wu,et al.  Determination of Constitutive Equation Parameters for Orthogonal Cutting through Pressure Bar Tests and FEA Method , 2012 .

[9]  Edoardo Capello,et al.  Residual stresses in turning. Part II: Influence of the machined material , 2006 .

[10]  V. Dattoma,et al.  On the evolution of welding residual stress after milling and cutting machining , 2006 .

[11]  Bang Yan Ye,et al.  Experimental Study on Pre-Stress Hard Cutting of Aero-Screw and its Machined Surface Residual Stress State , 2012 .

[12]  Rajiv Shivpuri,et al.  Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel , 2006 .

[13]  M. M. El-Khabeery,et al.  Residual stress distribution caused by milling , 1989 .

[14]  J. L. Lebrun,et al.  MACHINING RESIDUAL STRESSES IN AISI 316L STEEL AND THEIR CORRELATION WITH THE CUTTING PARAMETERS , 2002 .

[15]  D. Agard,et al.  Microtubule nucleation by γ-tubulin complexes , 2011, Nature Reviews Molecular Cell Biology.

[16]  Kang Li,et al.  An approach for analyzing and controlling residual stress generation during high-speed circular milling , 2013 .

[17]  Zhanqiang Liu,et al.  An experiment-based investigation on surface corrosion resistance behaviors of aluminum alloy 7050-T7451 after end milling , 2013 .

[18]  Shen Yung Lin,et al.  Residual Stress Prediction for High Speed Machining , 2012 .

[19]  Jia Li,et al.  An FEM study on residual stresses induced by high-speed end-milling of hardened steel SKD11 , 2009 .

[20]  Mohamed A. Elbestawi,et al.  From the basic mechanics of orthogonal metal cutting toward the identification of the constitutive equation , 2002 .

[21]  D. Umbrello,et al.  The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel , 2007 .

[22]  Martin Bäker,et al.  Determination of Johnson–Cook parameters from machining simulations , 2012 .

[23]  Gary S. Schajer,et al.  Overview of Residual Stresses and Their Measurement , 2013 .

[24]  H. Sasahara.  The effect on fatigue life of residual stress and surface hardness resulting from different cutting conditions of 0.45%C steel , 2005 .

[25]  Chih-Fu Wu,et al.  A residual-stress model for the milling of aluminum alloy (2014-T6) , 1995 .

[26]  Pingfa Feng,et al.  Identification of Material Constitutive Parameters Using Orthogonal Cutting Tests and Genetic Algorithm , 2011 .