Stress analysis and optimization of Nd:YAG pulsed laser processing of notches for fracture splitting of a C70S6 connecting rod

Abstract

The pulsed laser pre-processing of a notch as the fracture initiation source for the splitting process is the key mechanism of an advanced fracture splitting technology for C70S6 connecting rods. This study investigated the stress field of Nd:YAG pulsed laser grooving, which affects the rapid fracture initiation at the notch root and the controlled crack extension in the critical fracture splitting quality, to improve manufacturing quality. Thermal elastic-plastic incremental theory was applied to build the finite element analysis model of the stress field of pulsed laser grooving for fracture splitting based on the Rotary-Gauss body heat source. The corresponding numerical simulation of the stress field was conducted. The changes and distributions of the stress during pulsed laser grooving were examined, the influence rule of the primary technological parameters on the residual stress was analyzed, and the analysis results were validated by the corresponding cutting experiment. Results showed that the residual stress distribution was concentrated in the Heat-affected zone (HAZ) near the fracture splitting notch, which would cause micro-cracks in the HAZ. The stress state of the notch root in the fracture initiation direction was tensile stress, which was beneficial to the fracture initiation and the crack rapid extension in the subsequent fracture splitting process. However, the uneven distribution of the stress could lead to fracture splitting defects, and thus the residual stress should be lowered to a reasonable range. Decreasing the laser pulse power, increasing the processing speed, and lowering the pulse width can lower the residual stress. Along with the actual production, the reasonable main technological parameters were obtained.