Influence of customized cutting edge geometries on the workpiece residual stress in hard turning

2017 ◽  
Vol 232 (12) ◽  
pp. 2132-2139 ◽  
Author(s):  
Carlos EH Ventura ◽  
Bernd Breidenstein ◽  
Berend Denkena
Keyword(s):  
Residual Stress ◽  
Compressive Residual Stress ◽  
Hard Turning ◽  
Influence Factors ◽  
Contact Length ◽  
Cutting Edge ◽  
Stress Profile ◽  
Workpiece Surface ◽  
Residual Stress Profile ◽  
Initiation And Propagation

Depending on the intensity of mechanical and thermal loads during hard turning, compressive and/or tensile residual stress can be obtained. However, only compressive residual stress contributes to avoid crack initiation and propagation and increase fatigue life. In order to induce compressive residual stress in the workpiece surface and subsurface, cutting edge geometry is one of the most important influence factors. Taking this into account, the influence of new customized cutting edge geometries on the parameters of a hook-shaped residual stress profile (typical of a hard turning process) is investigated and possible causes for the encountered phenomena are explained. It was found that edge geometries, which provide an increase in contact length between tool and workpiece, lead to higher compressive residual stress in the subsurface and deeper affected zones.

The Effects of Process-Induced Residual Stress on Rolling Contact Stress of Hard Machined Components

Manufacturing ◽  
2003 ◽  
Author(s):  
Y. B. Guo ◽  
Mark E. Barkey ◽  
David W. Yen
Keyword(s):  
Residual Stress ◽  
Fatigue Damage ◽  
Compressive Residual Stress ◽  
Hard Turning ◽  
Stress Pattern ◽  
Rolling Contact ◽  
Small Scale ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Significant Difference

Compared with grinding, hard turning is a competitive manufacturing process that in many cases has substantial benefits. The most significant difference between hard turning and grinding is that hard turning may induce a relatively deep compressive residual stress. However, the interactions among the residual stress profile, applied load, and surface material, and their effects on component life in rolling contact are poorly understood. Further, contact stresses and strains are difficult to measure using the current experimental techniques due to the small-scale of the phenomena. A new simulation model of rolling contact has been developed to account for a process-induced residual stress profile. It has shown that distinct residual stress patterns hardly affect neither the magnitudes nor the locations of peak stresses and strains below the surface. However, they have a significant influence on surface deformations. The slope and depth of a compressive residual stress profile are key factors for rolling contact fatigue damage, which was substantiated by the available experimental data. Equivalent plastic strain could be a parameter to characterize the relative fatigue damage. The magnitudes of process-induced residual stress are reduced in rolling contact. The predicted residual stress pattern and magnitude agree with the test data in general. In addition, rolling contact is more sensitive to normal load and residual stress pattern than tangential load.

Characteristics of Residual Stress Profiles in Hard Turned Versus Ground Surfaces With and Without a White Layer

2008 ◽  
Author(s):  
A. W. Warren ◽  
Y. B. Guo
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Compressive Residual Stress ◽  
Hard Turning ◽  
Stress Measurement ◽  
White Layer ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Mechanical Products ◽  
Stress Profiles

Hard turning and grinding are competitive processes in many cases for manufacturing various mechanical products. Product performance is highly dependent on the process induced residual stresses. However, there exist some inconsistence regarding the true residual stress profiles generated by hard turning and grinding with and without the presence of a white layer. This study aims to clarify the pressing issues via an extensive residual stress measurement for five surface types: hard turned fresh (HTF), hard turned with a white layer (HTWL), ground fresh (GF), ground with a white layer (GWL), and as heat treated. The x-ray diffraction data revealed distinct differences in the residual stress profiles between the turned and ground surfaces. Specifically, the key findings are: (i) HTF surfaces generate a “hook” shaped residual stress profile characterized by surface compressive residual stress and maximum compressive residual stress in the subsurface, while GF surfaces only generate maximum compressive residual stress at the surface; (ii) HTWL surfaces generate a high tensile stress in the white layer, but has highly compressive residual stress in the deeper subsurface than the HTF surface; (iii) GWL surfaces only shift the residual stress to more tensile but does not affect the basic shape of the profile; (iv) Tensile residual stress in the HTWL surface is higher than that for the GWL one. However, the residual stress for the ground white layer does not become compressive and remains tensile in the subsurface; (v) Elliptical curve fitting is necessary for measuring residual stress for the HTWL surface due to the presence of shear stress induced severe Ψ splitting; (vi) Residual stresses by grinding show more scattering than those by hard turning; and (vii) Machining is the deterministic factor for the resulting residual stress magnitudes and profiles compared with the minor influence of initial residual stress by heat treatment.

A New Finite Element Approach Without Chip Formation to Predict Residual Stress Profile Patterns in Metal Cutting

2009 ◽  
Author(s):  
S. Anurag ◽  
Y. B. Guo ◽  
Z. Q. Liu
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Hard Turning ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Stress Prediction ◽  
Element Approach ◽  
Stress Profiles

Residual stress prediction in hard turning has been recognized as one of the most important and challenging tasks. A hybrid finite element predictive model has been developed with the concept of plowed depth to predict residual stress profiles in hard turning. With the thermo-mechanical work material properties, residual stress has been predicted by simulating the dynamic turning process followed by a quasi-static stress relaxation process. The residual stress profiles were predicted for a series of plowed depths potentially encountered in machining. The predicted residual stress profiles agree with the experimental one in general. A transition of residual stress profile has been recovered at the critical plowed depth. In addition, the effects of cutting speed, friction coefficient and inelastic heat coefficient on residual stress profiles have also been studied and explained.

Characteristics of Residual Stress Profiles in Hard Turned Versus Ground Surfaces With and Without a White Layer

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
A. W. Warren ◽  
Y. B. Guo
Keyword(s):  
Residual Stress ◽  
Compressive Residual Stress ◽  
Hard Turning ◽  
Cutting Tool ◽  
Stress Measurement ◽  
White Layer ◽  
Machining Process ◽  
Tensile Residual Stress ◽  
Stress Profile ◽  
Stress Profiles

Hard turning and grinding are precision processes in many cases for manufacturing various mechanical products. Product performance is highly dependent on the process induced residual stress. However, the basic differences in residual stress profiles generated by hard turning and grinding with and without the presence of a thermal white layer have not been well understood. This study aims to compare basic characteristics of the residual stress profiles using an extensive residual stress measurement for five surface types: hard turned fresh, hard turned with a white layer, ground fresh, ground with a white layer, and as heat treated. The X-ray diffraction data revealed distinct differences in the residual stress profiles for the five surface types. Hard turning with a sharp cutting tool generates a unique “hook” shaped residual stress profile characterized by compressive residual stress at the surface and maximum compressive residual stress in the subsurface, while “gentle” grinding only generates maximum compressive residual stress at the surface. The depth of compressive residual stress in the subsurface by hard turning is much larger than that by grinding. The high hertz pressure induced by the cutting tool in turning is the determining factor for the differences in residual stress. High tensile residual stress associates with the existence of a turned or a ground white layer. The coupled effects of high hertz pressure and rapid temperature change induced by tool wear play an important role in the resultant tensile residual stress. In addition, residual stress by grinding is more scattered than that by turning. Compared with the deterministic influence of machining process on the magnitudes and profiles of residual stress, the effect of heat treatment is minor.

Hook Shaped Residual Stress: The Effect of Tool Ploughing, and the Analysis of the Mechanical and Thermal Effects

2012 ◽  
Author(s):  
Xueping Zhang ◽  
Shenfeng Wu ◽  
C. Richard Liu
Keyword(s):  
Residual Stress ◽  
Formation Process ◽  
Chip Formation ◽  
Thermal Effects ◽  
Thermal Load ◽  
Compressive Residual Stress ◽  
Mechanical Load ◽  
Stress Profile ◽  
Fe Model ◽  
Residual Stress Profile

To investigate the unique hook-shaped residual stress profile generated from hard turning process, an improved orthogonal (2-D) Finite Element (FE) model is established to include the ploughing effect of cutting edge. The model is further decomposed into two FE sub-models (sub-model 1 and sub-model 2) to determine the thermal and mechanical effects on the residual stress profiles by saw-tooth chip formation process and honed-edge ploughing process respectively. The two FE sub-models are sequentially adopted to evaluate the compression effect induced by chip formation process and ploughing effect resulted from honed-edge cutting tool on residual stress profile. Their separated and integrated effects on residual stress hook-shape profile are addressed by comparing the predicted residual stresses by sub-model 1, sub-model 2, the two sub-models’ superposition, and the whole improved FE model. The results show that chip formation effect on residual stress profile happens earlier than the ploughing effect. Chip formation effect provides a foundation for the finalized residual stress profile by determining the maximum depth and magnitude of the compressive residual stress. Ploughing process generates much more thermal load to produce the tensile residual stress in hard turned surface and sequentially drives the final resultant residual stress into an obvious hook-shaped by modifying the previous compressive residual stress profile. The location with the maximum compressive residual stress is identified as the critical position to separate the mechanical load and thermal load generated from ploughing effect. The decomposition methodology on mechanical and thermal effects is proposed and thoroughly discussed in the paper.

Peripheral milling-induced residual stress and its effect on tensile–tensile fatigue life of aeronautic titanium alloy Ti–6Al–4V

2019 ◽  
Vol 123 (1260) ◽  
pp. 212-229 ◽  
Author(s):  
Dong Yang ◽  
Xiao Xiao ◽  
Yulei Liu ◽  
Jing Sun
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Surface Energy ◽  
Compressive Residual Stress ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Stress Profile ◽  
Peripheral Milling ◽  
Residual Stress Profile

ABSTRACTThe special application environment puts forward the higher requirement of reliability of parts made from titanium alloy Ti–6Al–4V, which is closely related to the machining-induced residual stress. For the fact of the non-linear distribution of residual stress beneath the machined surface, distribution of peripheral milling-induced residual stress and its effect on fatigue performance of titanium alloy Ti–6Al–4V are still confusing. In the present study, residual stress profile induced by peripheral milling of Ti–6Al–4V is first studied. And then, energy criteria are proposed to characterise the whole state of the residual stress field. Finally, the effects of residual stress profile and surface energy on tensile–tensile fatigue performance of titanium alloy Ti–6Al–4V are discussed. The conclusions were drawn that the variation trend of surface residual stress (σr,Sur), maximum compressive residual stress (σC,ax), location (hr0) and response depth (hry) of residual stress profile with cutting parameters showed a similar pattern for both measure directions those parallel (σ1) and perpendicular (σ3) to the cutting direction. Cutting speed and feed rate have a main effect on surface residual stress, and the depth of cut has little effect on all the four key factors of residual stress profile. With the increase of cutting speed and feed rate, machining-induced surface energy tends to become larger. But increasing the depth of cut caused the strain energy stored in unit time to decrease. Furthermore, the effect of depth of cut on surface energy was weakened when the value of cutting depth becomes larger. Both the surface compressive residual stress and the maximum compressive residual stress are beneficial for prolonging the fatigue life, while large value of machining-induced surface energy leads to a decrease of fatigue life. Analysis of variance result shows that maximum residual compressive stress has a greater impact on fatigue life than other residual stress factors.

Empirical modeling of compressive residual stress profile in shot peening TC17 alloy using characteristic parameters and sinusoidal decay function

2016 ◽  
Vol 232 (5) ◽  
pp. 855-866 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Junxue Ren
Keyword(s):  
Residual Stress ◽  
Shot Peening ◽  
Compressive Residual Stress ◽  
Empirical Modeling ◽  
Stress Profile ◽  
Characteristic Parameters ◽  
Decay Function ◽  
Function Model ◽  
Residual Stress Profile ◽  
Decay Function Model

This article introduces two comprehensive experimental models to predict the compressive residual stress profile induced in TC17 alloy after shot peening. Experiments are carried out utilizing one of experimental design techniques based on response surface methodology. Shot peening intensity and coverage are considered as two input parameters affecting compressive residual stress profile. The characteristic parameters model is created by regression analysis, which has the capability of predicting the four main characteristic parameters of a typical compressive residual stress profile. Based on this model, the absolute sensitivity of characteristic parameters with respect to shot peening intensity and coverage is analyzed. The sinusoidal decay function model is created with a proposition of that the compressive residual stress profile is a sinusoidal decay function of the depth beneath surface and the coefficients of this function are, in turn, functions of the two input shot peening parameters. The main advantage of sinusoidal decay function model over characteristic parameters model is that it provides the effect of shot peening parameters on the shape of the compressive residual stress profile. The two models have been checked for accuracy by two extra tests. The results show that the prediction errors of the four main characteristic parameters are within 20%, and the compressive residual stress profiles predicted by the sinusoidal decay function model are in consistent with experimental data.

Effects of process combinations of milling, grinding, and polishing on the surface integrity and fatigue life of GH4169 components

2019 ◽  
Vol 234 (3) ◽  
pp. 538-548
Author(s):  
Fang Quan ◽  
Zhitong Chen ◽  
Qiantong Li ◽  
Shimin Gao
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Boron Nitride ◽  
Compressive Residual Stress ◽  
High Cycle Fatigue ◽  
Cubic Boron Nitride ◽  
Stress Profile ◽  
Cycle Fatigue ◽  
Squeezing Effect ◽  
Residual Stress Profile

The nickel-based superalloy GH4169 is widely applied in the aviation industry due to its outstanding mechanical properties. However, many blades of GH4169 are still produced by milling and manual polishing, which is costly and unreliable. In this article, GH4169 superalloy components manufactured with combination processes of milling, grinding, and polishing were comparatively studied involving surface integrity and fatigue performance. Test results indicate that the final polishing is the most dominant process that influences the high-cycle fatigue life of GH4169 components. Samples produced via cubic boron nitride grinding and numerical control polishing with a diamond-rubber wheel exhibit fatigue limits of 150 MPa higher than the milled and manually polished samples. Cubic boron nitride grinding induces a considerable compressive residual stress profile with a magnitude of -930 MPa and a depth of 200 μm. Milling induces a typical “hook” residual stress profile with 318 MPa at the surface. Polishing affects the machined surface by two ways, the removal effect and the squeezing effect. The squeezing effect induces a shallow compressive residual stress with approximately −1000 MPa, therefore improves the surface condition. However, inevitable omissions, scratches, texture disorders, and knock marks in hand-polishing are the main causes of the unstable high-cycle fatigue life of hand-polished components.

Modeling of Residual Stress Profile in Finish Hard Turning

2006 ◽  
Vol 21 (1) ◽  
pp. 39-45 ◽  
Author(s):  
Jing Zhang ◽  
Steven Liang ◽  
Guowei Zhang ◽  
David Yen
Keyword(s):  
Residual Stress ◽  
Hard Turning ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Finish Hard Turning
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