Predictive Model for the Full Biaxial Surface and Subsurface Residual Stress Profiles from Turning

Jacobus, Kurt; DeVor, Richard E.; Kapoor, Shiv Gopal; Peascoe, R.

doi:10.1115/1.1372197

Cited by 14 publications

(6 citation statements)

References 13 publications

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“…x o y fixed with the cutting edge, as is demonstrated by Jacobus [16,17] and Su [11]. After coordinate transformation, the point ( , ) P x y becomes…”

Section: Periodically Varying Distributed Loadingmentioning

confidence: 96%

An Analytical Model of Residual Stress for Flank Milling of Ti-6Al-4V

2015

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Residual stress is one of the most critical parameters in surface integrity, which has a great impact on fatigue life of the machined components. While the flank milling of titanium alloy Ti-6Al-4V has been widely applied to the manufacture of jet engine for its high productivity in aerospace industry, prediction of residual stress induced by this process is seldom reported. In this paper, an analytical model of residual stress is proposed, based on comprehensive analysis of the mechanical loading during flank milling. For the first time, the sequential discontinuous variable loading feature of flank milling is taken into consideration. An incremental elasto-plastic method followed by a relaxation procedure is used to get the stress-strain history of an arbitrary point in the subsurface so as to predict the residual stress retained in the workpiece after several loading cycles. We find that during the last phase in which the machined surface is generated, the main load comes from the plough effect of cutting edge as the uncut depth approaches zero. The simulation results indicate that the flank milled surface shows more compressive residual stress in the axial direction than in the feed direction. To validate the prediction, a series of cutting tests are conducted on Ti-6Al-4V using finish parameters and X-ray diffraction is utilized to obtain the residual stress.

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“…x o y fixed with the cutting edge, as is demonstrated by Jacobus [16,17] and Su [11]. After coordinate transformation, the point ( , ) P x y becomes…”

Section: Periodically Varying Distributed Loadingmentioning

confidence: 96%

An Analytical Model of Residual Stress for Flank Milling of Ti-6Al-4V

2015

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“…Capello (2005) showed the effects of feed rate, tool nose radius, depth of cut and cutting edge angle on the axial residual stresses developed in turning, and developed a regression analysis to include these variables. Jacobus et al (2001) developed an extended 2-D model for turning, included the effects of feed and depth of cut and validated it. El-Axir (2002) proposed empirical equations postulating the dependence of residual stress profile and the depth of residual stress distribution as functions of the machining parameters using polynomial functions.…”

Section: A Summary Of Modelling Efforts and The Need For Predictive Pmentioning

confidence: 99%

A review of surface integrity in machining and its impact on functional performance and life of machined products

M’Saoubi¹,

Outeiro²,

Chandrasekaran³

et al. 2008

IJSM

233

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This paper presents an overview of the past research on Surface Integrity (SI) studies in the context of machined components from a range of work materials including stainless steels, Ni and Ti alloys, hardened steels for dies and moulds, bearings and automotive applications. Typical surface alterations such as phase transformations, microhardness and residual stress are discussed and correlated with the functional performance of the machined products. A summary of past and current modelling efforts is then presented along with projections for developing predictive models for SI and means for enhancing product sustainability in terms of its functional performance.

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“…[11] investigated residual stresses induced by orthogonal cutting in steels, analyzing the effect of the cutting speed, the feed rate, the tool geometry and coating; high residual stresses up to 960MPa were observed, as well as a strong hardening. Jacobus et al [12] developed a model to predict the full-biaxial surface and subsurface residual stresses; they found that an increase in feed rate or in depth of cut leads to an increase in the tensile character of normal stresses.…”

Section: The Surface Residual Stress Researchingmentioning

confidence: 99%

Experimental study of cumulative effect of residual stress on machined surface on HSM

Zhao

Wang

2009

SPIE Proceedings

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The high speed milling experiments are performed for hardened H13 die steel by using coated ball end milling cutter, the experiment was design for testing distribution properties of the residual stress in HSM. And the residual stress of the work-piece surface on the feed and cross feed direction are measured by the X-ray stress analyzer (X-stress 3000), and the distribution characteristics of residual stress is analyzed. The result shows that the residual stress presents gradient distribution on feed direction, and furthermore, the three-dimensional surface micro topography has been observed by the WykoNT9300, it shows that the micro topography has no close relation with the residual stress. In addition, the cumulative effect is discussed for explaining the phenomena. It could be one explanation for the residual stress gradient on the machined surface on mechanism.

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Predictive Model for the Full Biaxial Surface and Subsurface Residual Stress Profiles from Turning

Cited by 14 publications

References 13 publications

An Analytical Model of Residual Stress for Flank Milling of Ti-6Al-4V

An Analytical Model of Residual Stress for Flank Milling of Ti-6Al-4V

A review of surface integrity in machining and its impact on functional performance and life of machined products

Experimental study of cumulative effect of residual stress on machined surface on HSM

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