Study on Influences of Milling Process Optimization on Residual Stress Distribution for Machining Nickel-based Superalloys

doi:10.3969/j.issn.1004-132X.2024.04.006

Abstract

Abstract: The distribution of machining residual stress of nickel-based superalloys had a significant influence on the product quality. To achieve the control method of residual stress, the effects of processing parameters, tool parameters and mechanics-thermal coupling on the residual stress distribution of nickel-based superalloys were studied by means of simulation and experiments. It is found that the change of cutting depth will affect the radial and tangential residual stresses at the same time, and the change of feed rate per tooth mainly affects the residual stress in the feed direction. When the rotating speed increases, the temperature field becomes stronger, the materials are softened, the milling forces are decreased, and the thermal stress is gradually increased. The optimal proportioning scheme is obtained by the method of parameter combination proportioning. Taking the machining of engine blade parts as an example, the method based on parameter optimization may effectively control the residual stress of Nickel-based superalloys.

Key words: nickel-based superalloy, finite element, residual stress, processing parameter, cutting technology

摘要： 镍基高温合金加工残余应力分布状态对产品质量有显著影响，为实现对残余应力的控制，采用仿真与实验结合的方法，研究了工艺参数、刀具参数以及力热耦合对镍基高温合金残余应力分布的影响。研究结果表明：切削深度的改变会同时影响径向和切向的残余应力；每齿进给量的改变主要影响进给方向残余应力；当转速提高时，温度场作用变强，材料出现软化效应，铣削合力降低，热应力影响逐渐增强。采用参数组合配比的方法得到了最优的配比方案。发动机叶片零件加工实例表明，提出的基于参数优化配比的方法可有效控制镍基高温合金的加工残余应力。

关键词: 镍基高温合金, 有限元, 残余应力, 工艺参数, 切削加工工艺

CLC Number:

TH142
TG54

ZHANG Jinyang, XU Weichun, WANG Xiaohan, JIANG Xiaohui, GAO Shan. Study on Influences of Milling Process Optimization on Residual Stress Distribution for Machining Nickel-based Superalloys[J]. China Mechanical Engineering, 2024, 35(04): 624-635.

张金阳, 许伟春, 王笑含, 江小辉, 高山. 铣削工艺优化对镍基高温合金加工残余应力分布影响研究[J]. 中国机械工程, 2024, 35(04): 624-635.

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