An analytical model of residual stress in orthogonal cutting based on the radial return method

Wang, S.Q.; Li, J.G.; He, Chao; Laghari, Rashid Ali

doi:10.1016/j.jmatprotec.2019.05.015

Cited by 19 publications

(4 citation statements)

References 32 publications

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“…Such residual stresses could be attributed predominantly to the fast straining in the applied turning [17]. Several cutting parameters, including cutting speed, feed rate, cutting depth, tool wear, and the use of lubricant, have strong influence on the residual stress formation [16,17,21]. For linear regression, the precision factor R 2 provides a measurement of scattering or uncertainty.…”

Section: Residual Normal Stresses Determined Using the New Methods And Conventional Methodsmentioning

confidence: 99%

“…In addition, the deformation and friction also induce rapid heating and subsequent cooling of the machined surface in certain depth, which also contributes to the residual stresses. Residual stresses resulting from grinding, turning, and milling have been studied extensively [8,[11][12][13][14][15][16][17][18][19][20][21][22][23][24][25]. For example, Xin and Zhang reported residual tensile stresses of high strength steels after turning or high speed milling [13,14].…”

Section: Introductionmentioning

confidence: 99%

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A modified X-ray diffraction method to measure residual normal and shear stresses of machined surfaces

Luo

2022

Int J Adv Manuf Technol

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X-ray diffraction has been widely used in measuring surface residual stresses. A drawback of the conventional d ~ sin2ψ method is the increased uncertainty arising from sin2ψ splitting when a significant residual shear stress co-exists with a residual normal stress. In particular, the conventional method can only be applied to measure the residual normal stress while leaving the residual shear stress unknown. In this paper, we propose a new approach to make simultaneous measurement of both residual normal and shear stresses. Theoretical development of the new approach is described in detail, which includes two linear regressions, $$\frac{{d}_{\psi }+ {d}_{-\psi }}{2}$$ d ψ + d - ψ 2 ~sin2ψ and {dψ-d-ψ} ~ sin(2ψ), to determine the residual normal and shear stresses separately. Several samples were employed to demonstrate the new method, including turning-machined and grinding-machined cylindrical bars of a high strength steel as well as a flat sample of magnetron sputtered TiN coating. The machined samples were determined to have residual compressive normal stresses at both the axial and hoop directions as well as various scales of residual shear stresses. The TiN coating showed a high scale of residual compressive (normal) stress whereas the measured residual shear stress was extremely low. The new method showed significantly increased precision as compared to the conventional d ~ sin2ψ method.

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Section: Residual Normal Stresses Determined Using the New Methods And Conventional Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A modified X-ray diffraction method to measure residual normal and shear stresses of machined surfaces

Luo

2022

Int J Adv Manuf Technol

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“…According to incremental plasticity in plastic mechanics [42], the relationship between stress increment dσ and strain increment dε is typically described by the material's constitutive relation or plastic flow law. This relationship can be expressed in the following form:…”

Section: ( )(mentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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Ultrasonic vibration-assisted grinding (UVAG) technology has advantages in improving part surface integrity. Currently, the calculation of residual stresses in UVAG typically relies on commercial finite element software. However, because commercial finite element software is not specialized for residual stress calculations, the computational efficiency could be higher, and the accuracy could be better. This paper proposes a semi-analytical residual stress prediction model that considers the Influence of ultrasonic vibration. This paper introduces a semi-analytical residual stress prediction model that considers the impact of ultrasonic vibration. The model calculates the grinding mechanical and thermal stress fields separately using contact mechanics and finite difference methods. Based on Hertz's contact theory and Timoshenko's thermoelastic theory, a correlation model is provided for the association between mechanical and thermal loads with the internal stresses in the workpiece. Subsequently, the residual stress field is solved by considering the thermal-mechanical coupling effects in UVAG. Ultrasonic-assisted grinding experiments were conducted using 12Cr2Ni4A alloy steel as the object, and the maximum error between the predicted residual stresses by the model and the measured residual stresses was 10.5%.In addition, the detailed discussion on the Influence of grinding parameters on residual stress reveals that reducing the grinding wheel speed can significantly increase surface compressive residual stress. The paper's research shows that the residual stress distribution obtained by the new residual stress calculation model is correct, and the calculation efficiency is high, providing a new method for predicting residual stress in UVAG.

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“…Wang et al [21] established an analytical model of residual stress in orthogonal cutting and a radial return method was first used for the plastic stress calculation in their model. Furthermore, the residual stress induced by milling process can also be predicted, Wan et al [22] proposed a theoretical model to predict the residual stress distributions in the machined surface of the oblique milling process, where the 3D instantaneous contact status between the mill tool and workpiece was taken into consideration.…”

Section: Introductionmentioning

confidence: 99%

Modeling and optimization of surface residual stress profiles in milling of aluminum 7075-T6 alloy

Yue,

He,

et al. 2024

Int J Adv Manuf Technol

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An analytical model of residual stress in orthogonal cutting based on the radial return method

Cited by 19 publications

References 32 publications

A modified X-ray diffraction method to measure residual normal and shear stresses of machined surfaces

A modified X-ray diffraction method to measure residual normal and shear stresses of machined surfaces

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Modeling and optimization of surface residual stress profiles in milling of aluminum 7075-T6 alloy

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