Finite Element Analysis and Experimental Study on Welding Residual Stress of Heavy-Duty Turning Tool

Abstract

Because of its characteristics of good rigidity and strong ant-vibration, heavy-duty welding turning tools are widely applied in the rough machining of water chamber heads. However, welding residual stress is induced around the welding seam of the tool. During the heavy-duty machining, cracks easily occur due to an influence of impacts, high-temperature and thermal-mechanical loading, which causes tools failure. In this paper, ANSYS finite element model of heavy-duty cutting tools is established based on thermal elastic-plastic theory in order to analyze thermal stress field distribution in welding process. Secondly, actual welding residual stress distribution is obtained by the nano indentation experiment, verifying that the model can effectively analyze the stress and strain distribution. The welding tool failure mechanism is explored further. Finally, vibration aging and ultrasonic impact treatment methods are adopted to reduce welding residual stress of heavy-duty cutting tools. Two methods are compared for the influence of welding residual stress. Through the above research, finite element model can exactly reflect the welding residual stress distribution. The ultrasonic impact treatment is better than vibration aging treatment to reduce the welding residual stress and then extend their service life.