Machining-Induced Residual Stress: Experimentation and Modeling

Abstract

Controlled orthogonal and controlled oblique machining of annealed AISI 4340 have been undertaken in a design of experiments framework to investigate the machining-induced residual stresses resulting from these processes. The experimentation demonstrates significant simplifications in the machining-induced residual stress problem when the stresses are expressed in a coordinate system fixed in the tool and also indicates that the directions along the cutting edge and normal to the cutting edge of the tool are principal directions of the machining-induced residual stresses. Based on the experimental results, a plane strain thermoelastoplastic model of metal flow under the flank of a cutting tool is developed to predict the full in-plane biaxial residual stress profiles existing at and beneath the newly created surface. Calibrated results show favorable agreement with the experimental machining-induced residual stresses in annealed AISI 4340. [S1087-1357(00)00201-X]

Effect of Cooling and Shot Peening on Residual Stresses and Fatigue Performance of Milled Inconel 718

“…1(d). The formation of the tensile residual stresses on the milled surface is most likely to be of thermal origin associated with the great heat generation during machining [1]. From Fig.…”

“…Generally, tensile residual stresses are perceived to be detrimental to the fatigue performance, whereas compressive residual stresses have a beneficial effect. The formation of residual stresses in machining processes is essentially dominated by the plastic deformation in subsurface of the workpiece material together with the thermal impact at surface [1]. The thermally-induced residual stresses are usually in tension, thus sufficient cooling could effectively reduce the surface tension on a machined surface by lowering the cutting temperature, or even introduce compressive residual stresses [2].…”

Manufacturing Residual Stress States in Heat Treatment Simulation of Bearing Rings

“…The distribution of the residual stress state depends on various process parameters of all manufacturing steps in the complete process chain. For example, turning changes the residual stress state of a workpiece by superposition of thermal and mechanical loads which typically results in high tensile stresses at the surface and a small area with compressive stresses at a distance of some hundred micrometers under the surface [7]. The residual stress depth profile is mainly influenced by the machining parameters like feed, cutting depth, and cutting velocity [8].…”

Surface Integrity of Broached Inconel 718 and Influence of Thermal Exposure

“…They originate from elastic response to the inhomogeneous distribution of nonelastic strains as the consequence of the misfits either between different regions or between different phases [62]. The formation of residual stresses in machining processes is generally considered to be due to mainly plastic deformation in the sub-surface of the machined component and thermal impact at the surface [63]. Mechanically induced residual stresses could be either tensile or compressive, depending on the deformation that occurs at the tool/workpiece contact surface.…”