Predictive modeling of machining residual stresses considering tool edge effects

The surface integrity of machined components is defined by several characteristics, of which residual stress is extremely important. Residual stress is known to have an effect on critical mechanical properties such as fatigue life, corrosion cracking resistance, and dimensional tolerance of machined components. Among the factors that affect residual stress in machined parts are cutting parameters and tool geometry. This paper presents a method of modeling residual stress for hone-edge cutting tools in turning. The model utilizes analytical cutting force models in conjunction with an approximate algorithm for elastic–plastic rolling/sliding contact. Oxley’s cutting force model is coupled with a slip line model proposed by Waldorf to estimate the cutting forces, which are in turn used to estimate the stress distribution between the tool and the workpiece. A rolling/sliding contact model, which captures kinematic hardening, is used to predict the machining residual stresses. Additionally, a moving heat source model is applied to determine the temperature rise in the workpiece due to the cutting forces. The model predictions are compared with experimental data for the turning of AISI 52100. Force predictions compare well with experimental results. Similarly, the predicted residual stress distributions correlate well with the measured residual stresses in terms of magnitude of stresses and depth of penetration.