Finite Element Simulation of Residual Stress on the Surface in the Cutting Considering Tool Flank Wear

Abstract

Deformation caused by residual stress has been one of the main reasons influencing the machining accuracy, studies on machining residual stress should be performed. The tool flank wear on the cutting process has great influence on cutting heat which will infulence the distribution of residual stress, therefore,we should do the finite element simulation of cutting tool flank wear on the heat-affected firstly,then simulate and forecast the surface residual stress, studies on the effect of tool flank wear on the distribution of machined surface residual stress Johnson-Cook’s coupled thermal-mechanical model is used as workpiece material model, thermal-displacement coupled brick are used to mesh, while friction between tool and work piece uses modified Coulomb's law whose slide friction area is combined with sticking friction. By means of FEA, residual stress on the machined surface and cutting temperature under different tool flank wear conditions are obtained. The results are compared and analyzed, and then we can get the fundamental influencing law on machined surface residual stress of tool flank wear.