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

Abstract

A model to predict the full biaxial surface and subsurface residual stresses from the turning process is presented. The model formulation includes thermomechanical coupling, plastic heating, frictional heating, convection, conduction, thermal softening and strain hardening. Calibration and validation of the model are undertaken. The predictive model stands as a tool both to optimize the turning process based on the resulting residual stresses and also to gain an in-depth understanding of the physics of residual stress development from the turning process. In addition, thorough analysis of the experimental results reveals insight into the effects of feed and depth of cut on the surface and subsurface machining-induced residual stresses.