超声车削Monel K500高温合金残余应力模拟分析

Simulation Analysis of Residual Stress of Monel K500 Superalloy by Ultrasonic Turning

摘要: 加工工件中的残余应力对工件的疲劳寿命及其尺寸和几何精度都具有重要影响。超声波辅助车削降低了切削区域的温度，并降低了由于刀具和工件的不连续接触而产生的平均加工力。因此，超声振动辅助加工技术被引入到镍基合金切削加工过程中。文章通过单因素试验和正交试验探讨了不同切削深度、切削速度和进给量等对Monel K500高温合金残余应力的影响，并且使用专业有限元分析软件AdvantEdge对Monel K500高温合金进行超声车削二维模拟仿真。研究结果表明：各个因素在影响残余应力的数值上略有差异，其中进给量、振动频率影响最大。同时也通过试验得出了各个参数的最佳组合：B₄D₂A₃C₄E₄。研究结果为进一步优化镍基高温合金超声车削提供了参考依据。

Abstract: The residual stress in the machined workpiece has a significant influence on the fatigue life of the workpiece and its dimension and geometric accuracy. Ultrasonic-assisted turning reduces the temperature in the cutting zone and the average processing force due to the discontinuous contact between the tool and the workpiece. Therefore, ultrasonic vibration-assisted machining technology was introduced into the cutting process of nickel-based alloys. In this paper, the effects of different cutting depths, cutting speeds, and feed rates on the residual stress of the Monel K500 superalloy are discussed through single-factor experiments and orthogonal experiments. The two dimensional simulation of the ultrasonic turning of the Monel K500 superalloy is carried out using the professional finite element analysis software AdvantEdge. The results show that all factors have some influence on the residual stress, and the feed and vibration frequency have the greatest influence. At the same time, the best combination of individual parameters was determined through experiments: B₄D₂A₃C₄E₄. The research results provide a further reference for optimizing the ultrasonic turning of nickel-based superalloy.