The study of ultra-precision machining and residual stress for NiP alloy with different cutting speeds and depth of cut

The non-electrolytic NiP alloy is a special material developed to improve the machinability of nickel for ultra-precision cutting. The application of the coupled thermo-elastic–plastic model in a new cutting material often lacks the flow stress function. To overcome this problem, the data from an uni-axial tension experiment were used in this study to regress the flow stress and obtain the stress function. The simulation process achieved through the large deformation finite element method is used to analyze the distribution changes of the cutting force, strain and stress of the NiP workpiece under different orthogonal cutting conditions. The chip formation, the distribution of the temperature field of the workpiece and chip and the residual stress of the workpiece generated after cutting can all be obtained to determine the effect of these cutting conditions on the processing of the workpiece.