Abstract: Aiming at the surface quality problems of aeronautical aluminium alloy structural parts, a twodimensional orthogonal thermomechanical coupling model of 7050T7451 aluminium alloy based on JohnsonCook constitutive model was developed with finite element software ABAQUS. Under the same cutting parameters, the residual stresses of surface layer in conventional cutting (CC), vibration cutting in the cutting direction (CVC) and vibration cutting in the axial direction (AVC) were compared, and the effects of ultrasonic vibration cutting parameters, vibration frequency and vibration amplitude on the residual stresses were studied. The validity of the simulation model was verified by quoting the experimental data of residual stress in relevant literatures. The results indicate that the surface residual stress of the three cutting methods is compressive stress, which tends to the residual tensile stress along the depth direction. Vibration cutting can significantly increase the residual compressive stress of the workpiece surface. Surface residual compressive stress decreases with the increase of cutting speed and depth. With the increase of vibration amplitude or frequency, the surface residual compressive stress increases gradually.
Key words: residual stress; ABAQUS; orthogonal cutting; ultrasonic vibration