Simulation and Analysis of Residual Stress and Tool Wear in Mechanical Repeated Ruling Process

In order to study the superiority of mechanical repeated ruling grating blank compared with single mechanical ruling, the residual stress and tool wear are analyzed in this paper. In this paper, the residual stress theory of mechanical repeated ruling is first established, and then four groups of single factor test methods with constant total ruling depth are adopted in combination with the finite element simulation software. The first group is a single ruling test, and the last three groups are mechanical repeated ruling tests. The characteristics of residual stress and tool wear of raster blank were studied and compared. The analysis results show that the distribution of residual stress field and tool wear in mechanical repeated ruling grating blank are more regular than that in single one. Taking the above factors into consideration, the optimal combination scheme of one-time large ruling deep and two-time small ruling depth is adopted. The results of this study provide a theoretical basis and method guidance for the mechanical repeated ruling grating.

I. Introduction

On the basis of mechanical ruling technology, the mechanical repeated ruling process is to carry on the secondary ruling processing to the groove which is formed by the first ruling. This mean that the total ruling depth of a single mechanical ruling process is decomposed into a combination of "primary and secondary ruling depth" for repeated ruling of the groove. Many times rough, finishing has always been an important means to obtain high-quality machined surface. In 2010, Chen Dingyi et al [1] realized the efficient milling of sixsided drum mirror by installing three (thick, semi-fine, fine) knives in different radius of diamond milling cutter. In 2009, Yan Jiwang [2] and others of Japan studied the machining of coarse and fine secondary V-shaped groove with different cutting depth, which effectively avoided the phenomenon of flying edge and periodic bond fluctuation of non-electroplated NiP machined surface, and obtained high-quality micro-array structure; At the same time, the lower machining allowance in secondary machining will reduce the temperature rise of tool wear. In 2011, Sunil Kumar et al. of India used genetic algorithm to optimize the process parameters of multi-pass end milling, and obtained better surface roughness and tool life than single-pass milling [3]. Therefore, from the point of view of precision, high quality machined surface can be obtained by repeated machining with optimized machining allowance.