2024铝合金结构件残余应力的评估与变形预测

Evaluation of Residual Stress and Deformation Prediction of 2024 Aluminum Alloy Structural Parts

为了研究毛坯初始残余应力和铣削加工引入的表面残余应力对2024铝合金结构件加工变形的影响,通过有限元模拟和铣削试验对两框整体梁的加工变形进行了研究。考虑了毛坯的初始残余应力、铣削加工引入的表面残余应力以及这两个影响因素的综合作用对两框整体梁加工变形的影响。研究结果表明,毛坯的初始残余应力是两框整体梁产生加工变形的主要影响因素,初始残余应力与铣削加工引入的表面残余应力的综合作用加剧了变形,其中,由初始残余应力引起的变形占整体梁总变形的92%,表面残余应力引起的变形占整体梁总变形量的8%左右。并最终通过对两框整体梁的铣削加工试验验证了有限元模拟结果的准确性,对实际生产具有一定的参考价值。

In order to study the influence of the initial residual stress of the blank and the surface residual stress introduced by the milling process on the machining deformation of the 2024 aluminum alloy structural member, the deformation of the two-frame integral beam was studied by finite element simulation and milling test. The effects of the initial residual stress of the blank, the surface residual stress introduced by the milling process and the combined effects of the two influencing factors on the machining deformation of the two-frame monolithic beam are considered. The results show that the initial residual stress of the blank is the main influencing factor of the machining deformation of the two-frame monolithic beam. The combined effect of the initial residual stress and the surface residual stress introduced by the milling process exacerbates the deformation. Among them, the deformation caused by the initial residual stress accounts for 92% of the total beam deformation, the deformation caused by surface residual stress accounts for about 8% of the total beam deformation. Finally, the accuracy of the finite element simulation results is verified by the milling test of the two-frame monolithic beam, which has certain reference value for actual production.