Abstract
ABSTRACTResidual stresses become a huge obstacle to improve the quality of precision manufacturing. They impact the static strength, fatigue strength, and corrosion resistance of the manufactured parts seriously. Complexity of the residual stresses initialising, generating, and redistributing still makes it difficult to efficiently control their distribution. In this paper, a new approach based on stress wave is proposed to reveal the propagation mechanism of residual stress in depth during the milling process. An elastic longitudinal wave and a plastic longitudinal wave equations are established. The analytic expression of the stress wave in the real domain is obtained by Laplace transformation and Laplace inverse transformation. The propagation of stress waves in two-dimensional milling is simulated with Finite Element Method (FEM). A simulation case study has been performed in order to demonstrate the practicality and effectiveness of the proposed approach. The simulation results show that the simulated elastic wave propagation velocity agrees well with the theoretical one. The peak value of the milling stress wave decreases with the unloading. The influence of cutting thickness on the decay rate is larger than that of cutting speed.
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