The effect of process parameters and cutting tool shape on residual stress of SAE 52100 hard turned steel by high speed machining

Abstract

This study focused on determining the residual stress of SAE 52100 hard-turned steel. The objective was to evaluate and compare the effects of the cutting-edge geometry and cutting parameters (cutting speed, feed rate, and cutting depth) on the residual stresses of three different conventional inserts: S-WNGA08 0408S01020A 7025, T-WNGA08 0408T01020A 7025, and S-WNGA432S0330A 7025. Tests were performed on 60 samples of SAE 52100 hardened steel with an average hardness of 58.5 HRC. The circumferential residual stresses of the samples were measured by X-ray diffraction. A full factorial design of experiments with three factors and two levels each with two central points and a replicate was used for a statistical analysis. The most significant results were as follows: For all inserts, the measured residual stresses were compressive, which extended the tool lifespan. The residual stresses of the Type-S inserts were significantly influenced by the cutting speed and depth, and those of the Type-T insert were significantly influenced by the feed rate and cutting depth. In addition, the residual stresses of the insert 3 were more compressive than those of the other two types of inserts. In other words, residual stresses are more compressive for inserts with larger chamfer angles even as the principal residual stress profiles were all compressive. This work has also shown that it is possible to determine a significant statistical relationship between cutting forces and residual stresses, allowing force measurements to predict the residual stress without any information on process parameters.

Effect of thermo-mechanical loading on machining induced residual stresses in ultrasonic vibration assisted turning of Ti6Al4V alloy

“…In this section, the machining parameters effect on residual stresses is analyzed with respect to thermo-mechanical loading in UVAT process. 36 The thermo-mechanical aspects in UVAT process are analyzed by force components and cutting temperature from experimentation. Furthermore, residual stress distribution of machined components is analyzed with respect to thermo-mechanical phenomenon at same cutting conditions.…”

Optimization of forming force and Erichsen index using Taguchi design of experiments: Mathematical models and experimental validation

“…It was found that this method is widely used by researchers, for finding the effects of input factors on output parameters, 1 in various fields such as advanced manufacturing technologies 2–4 and conventional manufacturing processes. 5–10 On the first hand, the integration between this statistical method and numerical analysis was described in order to minimize the iteration number during simulation. Both finite element methods and design of experiments contribute to the optimization of the computed manufacturing processes.…”

Turning parameters effects in residual stresses of AISI 1045 steel

“…6,7 In this frame, X-ray diffraction (XRD) has been often employed for residual stress analysis in turning process. 1,7–14 Turning parameters that have presented a more considerable influence on residual stresses are tool nose radius, cutting speed, and feed. 7–11 An adequate rake angle choice has been reported to generate compressive residual stresses below surface and, in some situations, extend these values to deeper regions.…”