Generation mechanism of stress wave while milling aluminium 2219

ABSTRACT

Residual stresses become a huge obstacle to improve the quality of precision manufacturing. They impact the static strength, fatigue strength, and corrosion resistance of the manufactured parts seriously. Complexity of the residual stresses initialising, generating, and redistributing still makes it difficult to efficiently control their distribution. In this paper, a new approach based on stress wave is proposed to reveal the propagation mechanism of residual stress in depth during the milling process. An elastic longitudinal wave and a plastic longitudinal wave equations are established. The analytic expression of the stress wave in the real domain is obtained by Laplace transformation and Laplace inverse transformation. The propagation of stress waves in two-dimensional milling is simulated with Finite Element Method (FEM). A simulation case study has been performed in order to demonstrate the practicality and effectiveness of the proposed approach. The simulation results show that the simulated elastic wave propagation velocity agrees well with the theoretical one. The peak value of the milling stress wave decreases with the unloading. The influence of cutting thickness on the decay rate is larger than that of cutting speed.

KEYWORDS:

• Stress wave
• milling
• residual stress
• dynamic analysis

Acknowledgments

The authors acknowledge support by the National Natural Science Foundation of China (Grant No. 51175304), Shandong Provincial Natural Science Foundation of China (Grant No. ZR2017MEE052), and Shandong Provincial Key Research and Development Program of China (Grant No. 2019JZZY010441). Thanks for all the former research contributed to this paper.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

This work was supported by the National Natural Science Foundation of China[51175304]; Natural Science Foundation of Shandong Province[ZR2017MEE052]; and Shandong Provincial Key Research and Development Program of China[2019JZZY010441].

Notes on contributors

Zhaoliang Jiang

Zhaoliang Jiang, born in 1971, is a professor at Key Laboratory of High-efficiency and Clean Mechanical Manufacture of MOE, Shandong University, China. His research interests include precision manufacturing and industrial engineering. email: [email protected]

Guanglun Li

Guanglun Li, born in 1991, is currently a master candidate at Shandong University, China. He received his bachelor degree from Shandong University of Science and Technology, China, in 2016. His research interests include cutting process and precision manufacturing. email: [email protected]

Li Zhao

Li Zhao, born in 1987, is currently a PhD candidate at Shandong University, China. She received her master degree from University of Jinan, China, in 2014. Her research interests include milling and metal microstructure. email: [email protected]

Ziqun Zhang

Ziqun Zhang, born in 1991, is currently a master candidate at Shandong University, China. He received his bachelor degree from China University of Petroleum, China, in 2014. His research interests include milling and intelligent manufacturing. email: [email protected]