[J2010-5] Transactions of NAMRI/SME, 2010, Volume 38:33-40

A NEW FEM APPROACH TO PREDICT RESIDUAL STRESS PROFILES
IN HARD TURNING WITHOUT SIMULATING CHIP FORMATION
Z.Q. Liu, Y.B. Guo andS. Anurag   

Abstract: 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 thermomechanical work material properties, residual stress has been predicted by simulating the dynamic turning process followed by a quasistatic 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..

Keywords:  Residual stress profile, plowed depth, size effect, finite element modeling, hard turning.