A comprehensive review on residual stresses in turning

Elsheikh, Ammar H.; Shanmugan, S.; Muthuramalingam, T.; Thakur, Amrit Kumar; Essa, F.A.; Ibrahim, Ahmed Mohamed Mahmoud; Mosleh, Ahmed O.

doi:10.1007/s40436-021-00371-0

Cited by 45 publications

(17 citation statements)

References 202 publications

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“…Machining of hard-to-cut alloys such as titanium alloys and nickel-based super alloys is a challenging and troublesome task owing to the generation of higher cutting temperatures, as well as a difficulty in maintaining dimensional accuracy and minimizing surface roughness [ 2 , 3 , 4 , 5 , 6 ]. To machine the nickel-based super alloys effectively nontraditional machining techniques should be applied or at least machining variables and their range should be carefully selected [ 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different Cooling/Lubrication Conditions

Padhan

Das

et al. 2022

Materials

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The machining of nickel-based super alloys is challenging, owing to the generation of high cutting temperatures, as well as difficulty in maintaining dimensional accuracy and minimizing surface roughness, which compels the use of cutting fluids for reducing these issues due to efficient cooling/lubrication strategies. The present work investigates the comparative performance of four cooling/lubrication techniques: dry cutting, wet, minimum quantity lubricant (MQL) and compressed-air modes in turning Nitronic 60 steel using a new-generation SiAlON ceramic inserts. Several machinability parameters were analyzed for performance evaluation. For this purpose, 16 cycles of turning trials were performed based on Taguchi’s L16 orthogonal array experimental design by varying cutting conditions and lubrication modes. MQL exhibits beneficial effects as compared to the other lubrication conditions concerning low cutting force, improved surface finish, decreased cutting temperature, longer tool life, and lower white layer thickness on machined surface. Burr formation on the saw-tooth chip surface, as well as friction, greatly influenced the tool flank wear due to improper cooling and poor lubrication approach in dry, wet, and compressed-air-cooled machining environments in comparison to MQL-machining. From an economical perspective, the tool life in MQL machining improved by 11%, 72%, and 138% in the comparison with flooded, compressed-air, and dry conditions, respectively. The results of the study demonstrate that using the MQL system can help with heat extraction capability, and provide some promising outcomes.

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Section: Introductionmentioning

confidence: 99%

Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different Cooling/Lubrication Conditions

Padhan

Das

et al. 2022

Materials

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“…Machined components often exhibit tensile and/or compressive residual stresses, which can be induced by surface thermal gradients and/or by differential plastic deformation [ 39 , 40 ]. Tensile residual stresses in the surface and subsurface layers are usually detrimental to creep life, fatigue life, and stress corrosion cracking resistance, while compressive residual stresses are usually beneficial to the same properties [ 39 , 41 , 42 , 43 , 44 ].…”

Section: Introductionmentioning

confidence: 99%

Residual Stress Induced by Addition of Nanosized TiC in Titanium Matrix Composite

et al. 2022

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A hot pressing process was employed to produce titanium-based composites. Nanosized TiC particles were incorporated in order to improve mechanical properties of the base material. The amount of nanosized additions in the composites was 0.5, 1.0, and 2.0 wt %, respectively. Moreover, a TiB phase was produced by in situ method during sintering process. The microstructure of the Ti–TiB–TiC composites was characterized by scanning electron microscopy (SEM), electron probe microanalysis (EPMA), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD) techniques. Due to the hot pressing process the morphology of primary TiC particles was changed. Observed changes in the size and shape of the reinforcing phase suggest the transformation of primary carbides into secondary carbides. Moreover, an in situ formation of TiB phase was observed in the material. Additionally, residual stress measurements were performed and revealed a mostly compressive nature with the fine contribution of shear. With an increase in TiC content, linear stress decreased, which was also related with the presence of the TiB phase.

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“…One of the main causes of the problems occurring during machining of large-size details are relative vibrations between the tool and the workpiece [ 1 ], which lead to deteriorated quality of the machined surface, increased tool wear, or even a destruction of the tool or the workpiece [ 2 , 3 ]. The problems of thermal dynamics, which may result in increased machining error or the occurrence of unfavorable residual stresses [ 4 , 5 ] are also important. They are characteristic for high-speed machining of hard-to-cut workpieces [ 6 ].…”

Section: Introductionmentioning

confidence: 99%

Adjusting the Stiffness of Supports during Milling of a Large-Size Workpiece Using the Salp Swarm Algorithm

Kaliński

Galewski

Stawicka-Morawska

et al. 2022

Sensors

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This paper concerns the problem of vibration reduction during milling. For this purpose, it is proposed that the standard supports of the workpiece be replaced with adjustable stiffness supports. This affects the modal parameters of the whole system, i.e., object and its supports, which is essential from the point of view of the relative tool–workpiece vibrations. To reduce the vibration level during milling, it is necessary to appropriately set the support stiffness coefficients, which are obtained from numerous milling process simulations. The simulations utilize the model of the workpiece with adjustable supports in the convention of a Finite Element Model (FEM) and a dynamic model of the milling process. The FEM parameters are tuned based on modal tests of the actual workpiece. For assessing simulation results, the proper indicator of vibration level must be selected, which is also discussed in the paper. However, simulating the milling process is time consuming and the total number of simulations needed to search the entire available range of support stiffness coefficients is large. To overcome this issue, the artificial intelligence salp swarm algorithm is used. Finally, for the best combination of stiffness coefficients, the vibration reduction is obtained and a significant reduction in search time for determining the support settings makes the approach proposed in the paper attractive from the point of view of practical applications.

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A comprehensive review on residual stresses in turning

Cited by 45 publications

References 202 publications

Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different Cooling/Lubrication Conditions

Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different Cooling/Lubrication Conditions

Residual Stress Induced by Addition of Nanosized TiC in Titanium Matrix Composite

Adjusting the Stiffness of Supports during Milling of a Large-Size Workpiece Using the Salp Swarm Algorithm

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