Finite Element Simulation and Experimental Investigation on the Residual Stress Redistribution Induced Distortion During Blade Machining

Abstract

AbstractResidual stresses play a dominant role on the machining distortion problem. The effect of cutting parameters on the residual stress have been studied by many researchers. However, the redistribution of initial residual stress during machining is always been ignored. In this paper, a finite element model is established to investigate the stress redistribution coupling initial residual stress and cutting residual stress during the blade machining process. The model contains two parts: the heat treatment model and the machining model. The initial residual stress field by the quenching process is established in the heat treatment model. Then the machining process is simulated as the range of roughing machining, semi finishing and finishing. In addition, a cutting experiment is conducted to study the distribution of cutting residual stress on the blade surface. The result shows that the initial stress is more significant in the rough machining stage and the cutting residual stresses play a dominated role in the finishing machining stage of blade. The result is helpful to understand the redistribution mechanic during machining process better.KeywordsResidual stressMachiningFinite element simulationBlade