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Residual stresses computation induced by turning of AISI 4140 steel using 3D simulation based on a mixed approach

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Abstract

Residual stress is the most critical criteria of surface integrity affecting the fatigue life of manufactured components. Thermal, mechanical, and metallurgical effects generated during a machining process can cause this failure. In order to study this phenomenon, several simulation methods have been proposed in the literature, each with specific capabilities and accuracies. However, for a fundamental understanding, a new 3D numerical model is developed using a mixed approach that combines experimental data with numerical FEM model. This approach consists of replacing tool and chip formation with thermo-mechanical loadings equivalent to the tool action. The thermo-mechanical loadings move around the external surface of the workpiece and along the longitudinal direction in order to take into account the interactions between revolutions. It has been noted that the steady state was reached within three revolutions.

Based on this new approach, the present paper aims to investigate the model efficiency to predict residual stress with a reduced computational time. It is found that this mixed approach provides consistent results compared to experimental data obtained by X-ray diffraction.

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Authors and Affiliations

  1. Laboratoire de Tribologie et Dynamique des Systèmes, UMR 5513 CNRS/ECL/ENISE, Ecole Nationale d’Ingenieurs de Saint-Etienne, 58, rue Jean Parot, 42023, Saint-Étienne, France

    Anis Rami, Achref Kallel & Hedi Hamdi

  2. ENIM, LGM, Univ de Monastir, Avenue Ibn Eljazzar, 5000, Monastir, Tunisia

    Anis Rami & Salem Sghaier

  3. IPEIM, LGM, Univ de Monastir, Avenue Ibn Eljazzar, 5000, Monastir, Tunisia

    Sawsen Youssef

Authors
  1. Anis Rami
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  2. Achref Kallel
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  3. Salem Sghaier
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  4. Sawsen Youssef
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  5. Hedi Hamdi
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Correspondence to Anis Rami.

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Rami, A., Kallel, A., Sghaier, S. et al. Residual stresses computation induced by turning of AISI 4140 steel using 3D simulation based on a mixed approach. Int J Adv Manuf Technol 91, 3833–3850 (2017). https://doi.org/10.1007/s00170-017-0047-1

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  • DOI: https://doi.org/10.1007/s00170-017-0047-1

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