Experimental study of residual stress profiles evolution in face turning with flank wear progress

Face turning is a major process to generate a continuous profile such as a fillet geometry. Although face turning is a widely used process, lack of data on residual stress profiles evolution in face turning with tool flank wear progress motivated us to conduct this study. It is necessary to continuously perform three different turnings (longitudinal-fillet radius-face turnings) to produce a fillet radius in a helicopter rotor. Thus, the same cutting conditions used in longitudinal turning were applied to the face turning. Three levels of flank wears (new, VB150, VB300) were chosen to present a flank wear progress within an acceptable limit of VB in industry. X-ray diffraction method was also employed to analyze residual stress profiles on the face turned surfaces. Good repeatability among measured residual stress profiles was found. Significant penetration force increase with flank wear progress induced more compressive residual stress profiles, suggesting that penetration force plays an important role to generate residual stress profiles in face turning.