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Influence of tool geometric parameters on the residual stress of 7A04 aluminum alloy in LSEM

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Abstract

In order to explore the influence of tool geometric parameters on the residual stress of 7A04 aluminum alloy in large-strain extrusion machining (LSEM), the LSEM process of 7A04 aluminum alloy is simulated based on the Abaqus finite element (FE) analysis software; the residual stress distributions on the machined zone and continuous chips are obtained. The results show that, compared with the conventional cutting process, LSEM can yield a larger residual compressive stress or a smaller residual tensile stress; matching microtextures with the constraining tool and cutting tool reveals that adding a microtexture to only the constraining tool can effectively reduce the residual tensile stress or increase the residual compressive stress. The residual stress when λ = 0.75 is about 70% of that when λ = 1. The residual stress when λ = 0.5 is about 82% of that when λ = 1. If a smaller residual tensile stress or a larger residual compressive stress on the machined zone and continuous chips were considered an indicator of a better tool geometric parameter, then λ = 0.75, α = 15°, R = 0.3, and θ = 2°, and adding a rectangular-sectioned strip texture to only the constraining tool should be the best option.

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Funding

The work was supported by the National Natural Science Foundation of China (51705270), the National Natural Science Foundation of China (No. 51575289), the Natural Science Foundation of Shandong Province (No. ZR2016EEP03), the Applied Basic Research Program of Qingdao City (No. 19–6-2–69-cg), and Shandong Qingchuang Science and Technology Project (No. 2019KJB022).

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Authors and Affiliations

  1. College of Intelligent Manufacturing, Qingdao Huanghai University, Qingdao, 266520, China

    Zhang Ping, Yue Xiujie, Zhai Yanchun & Yu Xiao

  2. School of Electromechanical and Automotive Engineering, Yantai University, Yantai, 264000, China

    Wang Penghao

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  1. Zhang Ping
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  3. Yue Xiujie
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  5. Yu Xiao
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Contributions

The design of the overall scheme was completed by Zhang Ping. The design of the simulation scheme was completed by Wang Penghao. Data extraction was completed by Yue Xiujie. Language modification was completed by Zhai Yanchun and Yu Xiao.

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Correspondence to Zhang Ping.

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Ping, Z., Penghao, W., Xiujie, Y. et al. Influence of tool geometric parameters on the residual stress of 7A04 aluminum alloy in LSEM. Int J Adv Manuf Technol 120, 1707–1728 (2022). https://doi.org/10.1007/s00170-021-08574-2

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