基于AM60镁合金超精密车削残余应力仿真及实验

为改善AM60镁合金超精密车削加工工艺方法,采用金属切削理论和有限元分析法对超精密加工进行微米级仿真,建立三维有限元模型,并利用Advent Edge软件对残余应力进行仿真分析,研究切削参数对残余应力的影响规律,为验证仿真的结果,对AM60镁合金压铸件进行车削加工,并利用X射线衍射仪对已加工工件表面残余应力进行测量。仿真结果表明:单点金刚石刀具具有的超高导热性,对残余应力分布的热效应起到了一定的抑制作用。工件表面残余应力随着切削深度的增大而减小,随着切削速度的增加而增大。切削进给量对残余应力的影响最明显,切削速度及切削深度影响较小。通过实验测量结果对仿真结果进行验证,为AM60镁合金超精密车削工件表面残余应力的控制打下一定基础。

Simulation and Experiment of Residual Stress in Ultra-precision Turning of Magnesium Alloy Based on AM60

In order to improve the ultra-precision turning process of AM60 magnesium alloy, the metal cutting theory and finite element analysis method are used to simulate the ultra-precision turning process at the micron level, and a three-dimensional finite element model is established. The residual stress is simulated and analyzed by AdventEdge software. The influence of cutting parameters on the residual stress is studied. The simulation results were verified. The AM60 magnesium alloy die castings were machined by turning, and the surface residual stresses of the machined parts were measured by X-ray diffractometer. The simulation results show that the single-point diamond tool has super-high thermal conductivity, which can restrain the thermal effect of residual stress distribution. The residual stress on the workpiece surface decreases with the increase of cutting depth and increases with the increase of cutting speed. The influence of cutting feed on residual stress is most obvious, and cutting speed and cutting depth are less affected. The simulation results are validated by the experimental results, which lays a foundation for the control of residual stress on the surface of AM60 magnesium alloy ultra-precision turning workpiece.