椭圆振动切削的表面残余应力有限元模拟研究

Research on finite element simulation of surface residual stress based on elliptical vibration cutting

基于ALE(Arbitrary Lagrange-Euler)网格划分方法建立了椭圆振动切削有限元仿真模型,模拟了椭圆振动切削过程中切削力的变化规律,并将模拟获得的切削力平均值与相同工艺参数下Kim等人[1]所做的超声椭圆振动切削V型槽实验获得的切削力平均值比较,验证了有限元模型的正确性。利用建立的二维有限元模型模拟了椭圆振动切削和普通切削表面残余应力的分布情况,对比结果表明,采用椭圆振动切削的工件已加工表面在一定深度内形成了分布均匀的表面残余压应力,而普通切削情况下工件已加工表面并没有形成有效的残余压应力,从而预测了椭圆振动切削不仅能够降低切削力、延长刀具使用寿命,还对提高工件表面完整性、增强疲劳寿命和抗腐蚀能力等具有显著的作用。

A finite element simulation model for elliptical vibration cutting was developed. The material constitutive equation for vibration cutting was selected for simulating the cutting force of elliptical vibration cutting process, and then the average cutting force was compared with the experimental of same conditions of professor Kim to verify the correctness of the finite element model. Distribution of the surface residual stress of the elliptical vibration cutting and conventional was simulated by two-dimensional finite element model. The comparison results show that in a certain depth the surface residual compressive stress was found by elliptical vibration cutting without general cutting. To predict the elliptical vibration cutting can not only reduce the cutting force, extend tool life, but also to improve the surface integrity,enhanced fatigue life and resist corrosion etc.