Abstract: Aviation precision thin-walled parts have complex internal structures; and cutting induced residual stresses are important influencing factors for their precision stability. So, it is necessary to research on residual stresses in cutting. According to the thermal-elastic-plastic finite element theory, a 3D finite element model is established, the aviation material aluminum alloy Al2A12 is analyzed in a nonlinear elastic-plastic finite element simulation of orthogonal cutting, and residual stresses on the machined surface are predicted and calculated. By means of FEA, simulation results of residual stresses on the machined surface are obtained when different cutting speeds, tool angles, tool edge radiuses are used. By analyzing and comparing the results, the basic influence rules of various factors on residual stresses are found. Residual stresses induced by different cutting processes are simulated, the influence rules of a secondary cutting on residual stresses are obtained. At last, experiments are carried out to research the influences of different cutting parameters on residual stresses, and the validity of the 3D finite element model is proved.

Key words: Coupled thermo-mechanical model, Cutting experiment, Finite element simulation, Residual stress