Modeling of residual stresses in milling

Su, Jiann-Cherng; Young, Keith A.; Ma, Kong; Srivatsa, Shesh; Morehouse, John B.; Liang, Steven Y.

doi:10.1007/s00170-012-4211-3

Cited by 72 publications

(35 citation statements)

References 21 publications

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“…It has been a consensus that the mechanical impact in machining process is prone to introduce compressive residual stress while thermal impact is prone to cause tensile residual stress. When it comes to milling titanium alloys, however, most experimental results in literature show that the residual stress is compressive in nature [2,3] and the mechanical load dominates the residual stress formation especially at low cutting speed [11][12][13]. This can be attributed to the low thermal expansion coefficient of titanium alloy, which keeps the thermal stress at a relatively low level within a thin thermo-affected layer.…”

Section: Analytical Model Of Residual Stress In 2d Orthogonal Flank Mmentioning

confidence: 85%

“…Recently, Su et al [11] developed an analytical model for the residual stresses in milling, which incorporated the prediction of cutting force and temperature. The model performed well in predicting the trends of residual stresses for various milling conditions, although an assumption of largest depth of cut (DOC) during mechanic loading was made in the model, which led to overestimated forces at the surface.…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Analytical Model Of Residual Stress In 2d Orthogonal Flank Mmentioning

confidence: 85%

Section: Introductionmentioning

confidence: 99%

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

2015

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“…Calculate shearing forceF t F r and plowing forceP t P r by Equation (15), (16) Caculate mechanical stress σ ij of every point by Equation (2) Elastic loading by Equation (4) Yield Plastic loading by Equation (5) Unloading criterion by Equation (6) Calculate temperature field with an imaginary heat source…”

Section: Startmentioning

confidence: 99%

“…Ulutan, Alaca, and Lazoglu [13] used the finite element method to calculate the loads of the cutting process and then established the analytical method to calculate the residual stresses distribution during the orthogonal cutting process. The force and temperature in orthogonal cutting and milling were calculated by Su and Liang [14][15][16]. The algorithm proposed by McDowell was adopted to establish the residual stress analytical model and predict the distribution of residual stresses in the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Analytical modeling and experimental validation of residual stress in micro-end-milling

Peng

Dong

Yan

et al. 2016

Int J Adv Manuf Technol

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Micro-milling is widely used in aerospace and precision optical part manufacturing. Residual stress is an important index of surface integrity, which signally affects the performance of the micro-parts. This paper presents an analytical model to predict micro-milling residual stresses considering tool edge radius, material strengthening effects, and initial stress. A micro-milling cutting force prediction model is proposed, in which tool edge radius and material strengthening effects are taken into account. The imaginary heat source is utilized to estimate the temperature distribution in the workpiece. This model considers the prediction results of cutting force and temperature as thermomechanical loads experienced by the workpiece. Also, the effect of initial stress is taken into account during the estimation of residual stresses. After loading, unloading, and stresses release, the results of residual stresses in micro-milling are finally obtained. Both the micro-milling cutting force and residual stresses prediction results are validated by NAK80 steel on a three-axis ultraprecision machine. The predicted results capture the experiment results well in terms of distribution and value. Finally, the model is analyzed and discussed. The influences of tool edge radius, rake angle, feed per tooth, and spindle speed on residual stresses are preliminarily explored.

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“…In normal machining process, the temperature is controlled much lower than the phase changing temperature of the workpiece material, and thus the coupling thermomechanical loads are often used as the main sources of machining-induced residual stresses in the theoretical analysis [16,17]. Yao et al [18] analyzed the formation mechanism of machining-induced residual stresses in detail and specified the effects of cutting forces and temperature.…”

Section: Introductionmentioning

confidence: 99%

Energy criteria for machining-induced residual stresses in face milling and their relation with cutting power

Feng

Zhang

et al. 2015

Int J Adv Manuf Technol

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Machining-induced residual stresses can significantly influence the performance of machined parts, and many scholars have contributed efforts to measure, evaluate, predict, and control the distribution of residual stresses. In most published researches, the residual stresses are analyzed as the function of cutting parameters, tool parameters, or material properties, but any of these parameters cannot decide the distribution of residual stresses solo and directly. And the commonly used evaluation criteria, like surface value, peak value, and existing range, cannot reflect the overall distribution of residual stresses. In this paper, a new approach to study this issue was proposed, and the cutting loads, the cutting parameters, and the evaluation of residual stress field were unified to the concept of energy and its mutual transformation with mechanical work. The effective cutting power on the machined surface was analyzed, and the integral of strain energy density over depth and the power of stored strain energy were supposed to be the energy criteria of residual stress field. Face milling experiments were carried out, and the cutting forces and the in-depth residual stress distribution were measured. According to the methodology proposed, the results showed that with the increase of effective cutting power, the power of stored strain energy increases with growing rate, which means that the partition of cutting work stored as strain energy increases simultaneously. And the integral of strain energy density over depth grows linearly with the effective cutting power under the experimental conditions in this study.

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Modeling of residual stresses in milling

Cited by 72 publications

References 21 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

Analytical modeling and experimental validation of residual stress in micro-end-milling

Energy criteria for machining-induced residual stresses in face milling and their relation with cutting power

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