Research on Deformation Prediction of Camshaft Support Hole Surface Based on Boring Residual Stress Tensor

To investigate the hereditary evolution of machining-induced residual stress in ZL702A aluminum alloy during boring and to reduce stress-induced deformation in the camshaft support body, in this study multi-step boring experiments and residual stress measurements were carried out. Additionally, finite element simulation modeling and calculations of residual stresses on the bore wall were performed, along with research on loading methods of residual stress in components. By restricting secondary deformation of the bored parts using steel shims, effective surface residual stress data were obtained. The hereditary evolution of residual stresses was modeled and transferred between simulations using a multi-cut model and subroutine loading, improving computational efficiency. Based on the six-directional stress state conversion method in elasticity theory, stresses were converted, and machining deformations of components under different process parameters were predicted. The results indicate significant differences in residual stress measurements between cases where secondary deformation was restricted and unrestricted. The simulation results from the subroutine-based method established in this study show good consistency with both continuous cutting simulations and experimental results. When the feed rate f=0.1 mm/r and the rotational speed N=100 r/min, the residual stress-induced deformation of the component achieves optimal flatness and coaxiality errors.