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An analytical study on residual stresses in drilling of hardened steel

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Abstract

Drilled parts are prone to fatigue failure due to stress concentrating near the holes. As a result, the investigation of drilling-induced residual stresses can be of great importance. This study made an effort to present an analytical model to predict the distribution of residual stresses in drilling. The hole-making process was approximated by an orthogonal cutting model, with residual stresses being estimated using modified McDowell algorithm. The effects of drilling parameters, including cutting (feed and cutting speed), and drill bit (tool point and helix angles) parameters on surface residual stresses were investigated. Results revealed the formation of compressive residual stresses on hole surface in all conditions. The surface residual stresses decreased as the cutting speed and helix angle increased. However, an increase in feed and point angle caused residual stresses to rise. Nano-indentation method was used to validate the model. T test analysis demonstrated a good agreement between analytical and empirical results with an average difference of 23.1%. The only restriction was using the highest levels of cutting parameters due to ignoring white layer and phase change effects in the analytical model.

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Authors and Affiliations

  1. Tarbiat Modares University, P.O. Box 14115-363, Tehran, Iran

    Amir Rasti, Mohammad Hossein Sadeghi & Sina Sabbaghi Farshi

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  1. Amir Rasti
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  2. Mohammad Hossein Sadeghi
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  3. Sina Sabbaghi Farshi
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Correspondence to Mohammad Hossein Sadeghi.

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Rasti, A., Sadeghi, M.H. & Farshi, S.S. An analytical study on residual stresses in drilling of hardened steel. Int J Adv Manuf Technol 99, 2389–2405 (2018). https://doi.org/10.1007/s00170-018-2587-4

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  • DOI: https://doi.org/10.1007/s00170-018-2587-4

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