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Effect of cutting parameters on surface residual stresses in dry turning of AISI 1035 alloy

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Abstract

Residual stresses (RSes) induced by turning processes have a great effect on the material properties of the machined components and their abilities to withstand severe loading conditions (creep, fatigue, and stress corrosion cracking). The final state of RSes in a workpiece depends on its material and on the employed cutting parameters/conditions such as cutting speed, depth of cut, feed speed, cutting tool geometry, wear of the tool, cutting tool geometry, cutting tool coating, and cooling. This study introduces a comprehensive investigation of the effects of different cutting parameters, such as cutting speed (30, 60, and 90 m/min), feed (0.05, 0.1, and 0.3 mm/rev), and depth of cut (0.1, 0.5, and 1 mm) as well as cutting tool geometry such as cutting tool nose radius (0.397, 0.794, and 1.191 mm), and cutting tool coating (coated and uncoated) on the cutting force, maximum cutting temperature, surface microstructure, and surface residual stresses during cutting AISI 1035 alloy steel. The RSes were measured using X-ray diffraction technique. The experiments were designed using Taguchi method based on L18 orthogonal array, and the significance level of different cutting parameters as well as cutting tool properties have been determined via applying analysis of variance. Numerical simulations have been carried out using commercial machining software AdvantEdge.

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (E050902, E041604).

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Authors and Affiliations

  1. Mechanical Department, Kut Technical Institute, Middle Technical University, Baghdad, 10074, Iraq

    K. h. Salman & M. Ashham

  2. Production Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta, 31521, Egypt

    Ammar H. Elsheikh & Maher Rashad

  3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Ammar H. Elsheikh & Zhang Haiou

  4. Automotive and Tractors Engineering Department, Faculty of Engineering, Minia University, El-Minia, 61111, Egypt

    Mohammed Kamal Ahmed Ali

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Salman, K.h., Elsheikh, A.H., Ashham, M. et al. Effect of cutting parameters on surface residual stresses in dry turning of AISI 1035 alloy. J Braz. Soc. Mech. Sci. Eng. 41, 349 (2019). https://doi.org/10.1007/s40430-019-1846-0

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