Abstract: A three-dimensional finite element model including the flux thermal function and material removal is established in order to simulate the carbon arc air gouging process. The evolution of stress field and the characteristic of final residual stress distribution are analyzed. The results indicate that the evolution of the stress field and the residual stress distribution in the air-arc cutting process are similar to those of the welding process for flat plates. During the carbon arc air gouging process, the thermal expansion and cold contraction of the metals lead to the high tensile stresses in the materials around the groove, and high three-dimensional tensile stress concentration is obtained near the groove, which is adverse to the application of the carbon arc air gouging. On this basis, an analytical model that takes the initial residual stress into consideration is established, and which reveals the mechanism of the influences of the carbon arc air gouging on the initial stress of plate.

Key words: Carbon arc air gouging, Evolution of stress, Finite element model, Residual stress