Prediction and experimental research of abrasive belt grinding residual stress for titanium alloy based on analytical method

Abstract

As an important material, titanium alloy is widely used in the manufacture of aircraft engine parts, and its processed surface quality is critical to the performance of aircraft engines. Abrasive belt grinding (ABG) is a kind of elastic grinding, which plays a significant role in improving titanium alloys’ surface integrity. To validate the mathematical model’s effectiveness from the grinding parameters to the surface residual stress after grinding, firstly, according to the molecular dynamics theory and ABG process, a physical model of titanium alloy ABG molecular system is proposed, and the embedded atom method is chosen as the interatomic potential of titanium alloy. Secondly, combined with the mathematical expression model of residual stress, the surface residual stress is characterized, and the heat correction coefficient is proposed to modify the mathematical model. Finally, based on molecular dynamics, the simulation of grinding residual stress and the grinding experiment is carried out for titanium alloy thin-walled parts. The results of simulation and experiment show that the trend of simulation results is similar to the experiment results. The simulation model can better represent the change rule of ABG surface residual stress for the titanium alloy material, but the average error rate is up to 15.01% due to the systematic error between the two. After correction, the average error rate between the simulation values and experiment values of residual stress on the surface decreases to 4.44%; the effectiveness of the mathematical model is verified.