Skip to main content
SpringerLink
Log in

Prediction of machining-induced residual stress in orthogonal cutting of Ti6Al4V

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In addition to having significant effects on the service life of machined parts, residual stress can cause large deformations during machining of thin-walled parts in aerospace field. The residual stress in machined part surface layer is induced by mechanical and thermal stress in the machining process of parts. Therefore, it is essential to accurately predict the generated residual stress due to the machining process. To address this issue, an improved prediction model of the residual stress for orthogonal cutting process based on analytical method is presented by taking the mechanical and thermal stress into consideration. Oxley’s cutting force model and Waldorf’s plowing force model are used to calculate the chip formation force and plowing force based on the contact mechanics, Johnson-Cook constitutive model, and slip line theory. The cutting temperature is predicted according to our previous work based on the Huang-Liang model and the Komanduri-Hou model. The final residual stress is predicted by calculating the loading and relaxation of mechanical and thermal stress. The presented prediction method of residual stress is validated by orthogonal cutting of a Ti6Al4V pipe. It is found that the prediction values of the presented model show a good agreement with the experimental results, which indicates that the presented model can be adopted to predict the residual stress of Ti6Al4V during orthogonal cutting.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Henriksen EK (1951) Residual stresses in machined surfaces. Trans ASME J Eng Ind 73:69–76

    Google Scholar 

  2. Liang SY, Su JC (2007) Residual stress modeling in orthogonal machining. CIRP Ann Manuf Technol 56(1):65–68. https://doi.org/10.1016/j.cirp.2007.05.018

    Article  Google Scholar 

  3. Ulutan D, Erdem Alaca B, Lazoglu I (2007) Analytical modelling of residual stresses in machining. J Mater Process Technol 183(1):77–87. https://doi.org/10.1016/j.jmatprotec.2006.09.032

    Article  Google Scholar 

  4. Lazoglu I, Ulutan D, Alaca BE, Engin S, Kaftanoglu B (2008) An enhanced analytical model for residual stress prediction in machining. CIRP Ann Manuf Technol 57(1):81–84. https://doi.org/10.1016/j.cirp.2008.03.060

    Article  Google Scholar 

  5. Sasahara H, Obikawa T, Shirakashi T (2004) Prediction model of surface residual stress within a machined surface by combining two orthogonal plane models. Int J Mach Tools Manuf 44(7–8):815–822. https://doi.org/10.1016/j.ijmachtools.2004.01.002

    Article  Google Scholar 

  6. Outeiro JC, Umbrello D, M’Saoubi R (2006) Experimental and numerical modelling of the residual stresses induced in orthogonal cutting of AISI 316L steel. Int J Mach Tools Manuf 46(14):1786–1794. https://doi.org/10.1016/j.ijmachtools.2005.11.013

    Article  Google Scholar 

  7. Grissa R, Zemzemi F, Fathallah R (2018) Three approaches for modeling residual stresses induced by orthogonal cutting of AISI316L. Int J Mech Sci 135:253–260. https://doi.org/10.1016/j.ijmecsci.2017.11.029

    Article  Google Scholar 

  8. Mittal S, Liu CR (1998) A method of modeling residual stresses in superfinish hard turning. Wear 218(1):21–33. https://doi.org/10.1016/S0043-1648(98)00201-4

    Article  Google Scholar 

  9. Masoudi S, Amini S, Saeidi E, Eslami-Chalander H (2015) Effect of machining-induced residual stress on the distortion of thin-walled parts. Int J Adv Manuf Technol 76(1):597–608. https://doi.org/10.1007/s00170-014-6281-x

    Article  Google Scholar 

  10. Nespor D, Denkena B, Grove T, Böß V (2015) Differences and similarities between the induced residual stresses after ball end milling and orthogonal cutting of Ti–6Al–4V. J Mater Process Technol 226:15–24. https://doi.org/10.1016/j.jmatprotec.2015.06.033

    Article  Google Scholar 

  11. Merwin JE, Johnson KL (1963) An analysis of plastic deformation in rolling contact. Proc Inst Mech Eng 177(1):676–690. https://doi.org/10.1243/pime_proc_1963_177_052_02

    Article  Google Scholar 

  12. Barash MM, Schoech WJ (1970) A semi-analytical model of the residual stress zone in orthogonal machining. Proc. 11th Int. MTDR Conf: 603–613

  13. Agrawal S, Joshi SS (2013) Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel. J Manuf Process 15(1):167–179. https://doi.org/10.1016/j.jmapro.2012.11.004

    Article  Google Scholar 

  14. Ji X, Zhang X, Liang SY (2014) Predictive modeling of residual stress in minimum quantity lubrication machining. Int J Adv Manuf Technol 70(9):2159–2168. https://doi.org/10.1007/s00170-013-5439-2

    Article  Google Scholar 

  15. Huang K, Yang W, Chen Q (2015) Analytical model of stress field in workpiece machined surface layer in orthogonal cutting. Int J Mech Sci 103:127–140. https://doi.org/10.1016/j.ijmecsci.2015.08.020

    Article  Google Scholar 

  16. Huang XD, Zhang XM, Ding H (2016) A novel relaxation-free analytical method for prediction of residual stress induced by mechanical load during orthogonal machining. Int J Mech Sci 115-116:299–309. https://doi.org/10.1016/j.ijmecsci.2016.06.024

    Article  Google Scholar 

  17. Fuh KH, Wu CF (1995) A residual-stress model for the milling of aluminum alloy (2014-T6). J Mater Process Technol 51(1):87–105. https://doi.org/10.1016/0924-0136(94)01355-5

    Article  Google Scholar 

  18. Fergani O, Lazoglu I, Mkaddem A, Mansori M, Liang SY (2014) Analytical modeling of residual stress and the induced deflection of a milled thin plate. Int J Adv Manuf Technol 75(1):455–463. https://doi.org/10.1007/s00170-014-6146-3

    Article  Google Scholar 

  19. Ma Y, Feng P, Zhang J, Wu Z, Yu D (2016) Prediction of surface residual stress after end milling based on cutting force and temperature. J Mater Process Technol 235:41–48. https://doi.org/10.1016/j.jmatprotec.2016.04.002

    Article  Google Scholar 

  20. Huang X, Zhang X, Ding H (2017) An enhanced analytical model of residual stress for peripheral milling. Proc CIRP 58:387–392. https://doi.org/10.1016/j.procir.2017.03.245

    Article  Google Scholar 

  21. Zhou R, Yang W (2017) Analytical modeling of residual stress in helical end milling of nickel-aluminum bronze. Int J Adv Manuf Technol 89(1):987–996. https://doi.org/10.1007/s00170-016-9145-8

    Article  Google Scholar 

  22. Wan M, Ye XY, Yang Y, Zhang WH (2017) Theoretical prediction of machining-induced residual stresses in three-dimensional oblique milling processes. Int J Mech Sci 133:426–437. https://doi.org/10.1016/j.ijmecsci.2017.09.005

    Article  Google Scholar 

  23. Liang SY, Hanna CR, Chao RM (2008) Achieving machining residual stresses through model-driven planning of process parameters. Trans North Am Manuf Res Inst SME 36:445–452

    Google Scholar 

  24. Huang K, Yang W, Ye X (2018) Adjustment of machining-induced residual stress based on parameter inversion. Int J Mech Sci 135:43–52. https://doi.org/10.1016/j.ijmecsci.2017.11.014

    Article  Google Scholar 

  25. Huang K, Yang W (2016) Analytical modeling of residual stress formation in workpiece material due to cutting. Int J Mech Sci 114:21–34. https://doi.org/10.1016/j.ijmecsci.2016.04.018

    Article  Google Scholar 

  26. Oxley PLB (1989) The mechanics of machining: an analytical approach to assessing machinability. Ellis Horwood

  27. Johnson R, Cook WK (1983) A constitutive model and data for metals subjected to large strains high strain rates and high temperatures. The 7th International Symposium on Ballistics. The Hague, pp 541–547

  28. Huang Y, Liang SY (2005) Cutting temperature modeling based on non-uniform heat intensity and partition ratio. Mach Sci Technol 9(3):301–323. https://doi.org/10.1080/10910340500196421

    Article  Google Scholar 

  29. Komanduri R, Hou ZB (2000) Thermal modeling of the metal cutting process: part I—temperature rise distribution due to shear plane heat source. Int J Mech Sci 42(9):1715–1752. https://doi.org/10.1016/S0020-7403(99)00070-3

    Article  MATH  Google Scholar 

  30. Komanduri R, Hou ZB (2001) Thermal modeling of the metal cutting process—part II: temperature rise distribution due to frictional heat source at the tool–chip interface. Int J Mech Sci 43(1):57–88. https://doi.org/10.1016/S0020-7403(99)00104-6

    Article  MATH  Google Scholar 

  31. Komanduri R, Hou ZB (2001) Thermal modeling of the metal cutting process—part III: temperature rise distribution due to the combined effects of shear plane heat source and the tool–chip interface frictional heat source. Int J Mech Sci 43(1):89–107. https://doi.org/10.1016/S0020-7403(99)00105-8

    Article  MATH  Google Scholar 

  32. Shan C, Zhang X, Shen B, Zhang D (2019) An improved analytical model of cutting temperature in orthogonal cutting of Ti6Al4V. Chin J Aeronaut 32(3):759–769. https://doi.org/10.1016/j.cja.2018.12.001

    Article  Google Scholar 

  33. Saif MTA, Hui CY, Zehnder AT (1993) Interface shear stresses induced by non-uniform heating of a film on a substrate. Thin Solid Films 224(2):159–167. https://doi.org/10.1016/0040-6090(93)90427-Q

    Article  Google Scholar 

  34. Adibi-Sedeh AH, Madhavan V, Bahr B (2003) Extension of Oxley’s analysis of machining to use different material models. J Manuf Sci Eng 125(4):656–666. https://doi.org/10.1115/1.1617287

    Article  Google Scholar 

  35. Altintas Y (2012) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge University Press, New York

    Google Scholar 

  36. Wang ZG, Rahman M, Wong YS, Li XP (2005) A hybrid cutting force model for high-speed milling of titanium alloys. CIRP Ann 54(1):71–74. https://doi.org/10.1016/S0007-8506(07)60052-3

    Article  Google Scholar 

  37. Waldorf DJ, Devor RE, Kapoor SG (1998) A slip-line field for ploughing during orthogonal cutting. J Manuf Sci Eng 120(4):693–699. https://doi.org/10.1115/1.2830208

    Article  Google Scholar 

  38. Johnson KL (1986) Contact mechanics. Cambridge University Press, Cambridge

    Google Scholar 

  39. Ji X, Li BZ, Liang SY (2018) Analysis of thermal and mechanical effects on residual stress in minimum quantity lubrication (MQL) machining. J Mech 34(1):41–46. https://doi.org/10.1017/jmech.2016.14

    Article  Google Scholar 

  40. Jiang Y, Sehitoglu H (1994) An analytical approach to elastic-plastic stress analysis of rolling contact. J Tribol 116(3):577–587. https://doi.org/10.1115/1.2928885

    Article  Google Scholar 

Download references

Acknowledgments

The authors wish to thankfully acknowledge Zhuzhou Cemented Carbide Cutting Tools Co., Ltd. (ZCCCT), for providing cutting tools for our experiments.

Funding

This work was co-supported by the National Science and Technology Major Project of China (No. 2018ZX04005001) and the Seed Foundation of Innovation and Creation for Graduate Students in the Northwestern Polytechnical University (No. G2019KY04104).

Author information

Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi’an, 710072, Shaanxi, China

    Chenwei Shan, Menghua Zhang, Shengnan Zhang & Jie Dang

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Chenwei Shan, Menghua Zhang & Shengnan Zhang

  3. AECC Commercial Aircraft Engine Co., Ltd., Shanghai, China

    Jie Dang

Authors
  1. Chenwei Shan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Menghua Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shengnan Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jie Dang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chenwei Shan.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shan, C., Zhang, M., Zhang, S. et al. Prediction of machining-induced residual stress in orthogonal cutting of Ti6Al4V. Int J Adv Manuf Technol 107, 2375–2385 (2020). https://doi.org/10.1007/s00170-020-05181-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05181-5

Keywords

Search

Navigation