Modeling of Residual Stresses by Correlating Surface Topography in Machining of AISI 52100 Steel

Abstract

The residual stresses could affect the ability of components to bear loading conditions and also the performance. The researchers considered workpiece surface as a plane and ignored the effect of surface topography induced by the intermittent cutting process when modeling residual stresses. The aim of this research develops an analytical model to predict workpiece residual stresses during intermittent machining by correlating the effect of surface topography. The relative motions of tool and workpiece are analyzed for modeling thermal-mechanical and surface topography. The influence of dynamic cutting force and thermal on different positions of surface topography is also considered in the analytical model. Then, the residual stresses model with the surface topography effect can be developed in intermittent cutting. The analytical models of dynamic cutting force, surface topography, and residual stresses are verified by the experiments. The variation trend of evaluated values of the residual stress of workpiece is basically consistent with that of measured values. The compressive residual stress of the workpiece surface in highest point of the surface topography is higher than that in the lowest point.