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首页> 外文会议>ASME International Mechanical Engineering Congress and Exposition >A Finite Element Analysis Based Compliance Method Coupled with Wet Etching to Determine Residual Stress in High Speed Milling
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A Finite Element Analysis Based Compliance Method Coupled with Wet Etching to Determine Residual Stress in High Speed Milling

机译：基于有限元分析的基于湿法蚀刻的合规性方法，以确定高速铣削的残余应力

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摘要

High speed milling (HSM) is widely used in automotive and aerospace industries in fabricating mechanical components from high strength aluminum and other alloys due to high productivity and good surface finish. HSM induced residual stresses may significantly impact the fatigue life and corrosion resistance of the machined components. Traditional methods of residual stress (RS) measurement, such as hole drilling, X-ray diffraction, and neutron diffraction, are very time consuming and expensive, especially for the shallow subsurface (usually < 100 μm) of a machined component. The compliance method provides a convenient alternative to these approaches to determine the residual stress distributions in the subsurface. However, the compliance method using wire EDM is prone to experimental errors. In addition, the traditional approach to calculate compliance function is very complex. This paper presents a new wet etching approach to obtain strains as a function of slot depth introduced in the subsurface. The strain readings were collected from a strain gauge mounted on the specimen surface near the slot edge. The compliance function can be conveniently calculated by simulating slot cutting using the finite element method via a Legendre polynomial subroutine as the applied load. These calculated compliance functions and measured strain values at different depths were used as inputs into a program to calculate residual stress. This leads to much a faster and less expensive method of determining residual stresses when compared with the traditional methods of residual stress determination. The capability of this new approach was demonstrated by high speed milling 6061-T651 and 7050-T7451 aluminum alloys. A design of experiment (DOE) method was adopted to conduct fifty-four cutting conditions with three levels of cutting speed, feed rate, and depth of cut. Residual stress profiles with twelve data points with spatial resolution as small as 1 μm in the subsurface were then obtained using this new approach. Residual stress sensitivity to cutting conditions was investigated. In addition, subsurface microstructure and microhardness were characterized.
机译：高速铣削（HSM）广泛应用于汽车和航空航天行业，在高强度铝和其他合金中制造机械部件，由于高生产率和良好的表面光洁度。 HSM诱导的残余应力可以显着影响机加工部件的疲劳寿命和耐腐蚀性。传统的残余应力（RS）测量方法，例如孔钻孔，X射线衍射和中子衍射，非常耗时且昂贵，特别是对于机加工部件的浅地下（通常<100μm）。顺应性方法为这些方法提供了一种方便的替代方法，以确定地下中的残余应力分布。但是，使用电线EDM的合规方法容易发生实验误差。此外，传统的计算合规功能的方法非常复杂。本文介绍了一种新的湿法蚀刻方法，以获得作为地下引入的槽深的函数的菌株。从安装在槽边缘附近的样品表面上的应变仪收集应变读数。可以通过使用有限元方法通过Legendre多项式子程序作为所施加的负载来模拟槽切割来方便地计算顺应功能。这些计算的顺应性函数和不同深度的测量应变值被用作计算残余应力的程序中的输入。与传统的残余应力测定方法相比，这导致多大较快地确定残留应力的方法。通过高速铣削6061-T651和7050-T7451铝合金证明了这种新方法的能力。采用实验（DOE）方法设计，进行五十四个切割条件，具有三个水平的切割速度，进料速率和切割深度。然后，使用这种新方法获得具有4个具有空间分辨率的十二个数据点的残余应力分布。研究了对切割条件的残余应力敏感性。另外，表征了地下微观结构和微硬度。

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