Study on Finite Element Method of Stress Field in Aluminum Alloy High-Speed Milling Process

Three-dimensional numerical simulation model has been built by means of Advantage FEM. Perform simulation the stress fields of 7050-T7451 aluminum alloy in high speed milling process at the speed range of 628 m/min∼5946 m/min. The dynamic change and speed's influence of stress fields and residual stress in machined layer is systematically analyzed. Some conclusions were drawn. With the cutting process development, the stress field converts to the stress state that crushing stress occupies a leading position. The magnitudes of crushing stress in all directions reduce with milling processes as the effect of Thermal-Mechanical-Coupled weakens; With the cutting speed increasing the magnitudes of crushing stress in all directions fluctuate near -950Mpa first, and then increase at the speed of 3000m/min; The residual pulling stress beneath the surface 0.03mm has been found and the magnitude increases with the cutting speed. A good agreement was obtained between predictions and experiments. (paper)