Skip to main content
SpringerLink
Log in

Numerical and experimental investigations on residual stress evolution of multiple sequential cuts in turning

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

Abstract

Residual stress is of great importance on the fatigue life of components; nevertheless, most of the simulations of turning operation focus on the first cut and ignore the evolution of residual stress in sequential cutting. The present study aims to explore the surface residual stress profile along the feed direction during longitudinal turning, to understand the impact of sequential cuts on turning-induced residual stress. A Coupled Eulerian–Lagrangian (CEL)-based three-dimensional (3D) numerical model is employed to stably predict the evolution of residual stress of multiple sequential cuts in turning integrated with complete material removal process of each cut. The effectiveness and accuracy of the proposed model are verified though the good agreement between simulated and measured results. The results show that the surface residual stress gradually decreases with increasing cutting sequence under the condition of different tool nose radius and feed rates. It is also found that the main reason of this phenomenon is the residual stress state generated by the former tool path. For a single case, the drop of tensile residual stress from the first cut to the third cut can be more significant when a larger feed rate is employed.

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
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

References

  1. Elsheikh A, Shanmugan S, Muthuramalingam T, Thakur A, Essa F, Ibrahim A, Mosleh A (2022) A comprehensive review on residual stresses in turning. Adv Manuf 10:287–312. https://doi.org/10.1007/s40436-021-00371-0

    Article  Google Scholar 

  2. López-Gálvez H, Soldani X (2020) Determination of optimum numerical parameters in a 3D model of finish turning operation applied to Inconel 718. Simul Model Pract Theory 99:102035. https://doi.org/10.1016/j.simpat.2019.102035

    Article  Google Scholar 

  3. Parida A, Maity K (2020) FEM and experimental analysis of thermal assisted machining of titanium base alloys. Measurement 152:107292. https://doi.org/10.1016/j.measurement.2019.107292

    Article  Google Scholar 

  4. 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 

  5. Girinon M, Valiorgue F, Robin V, Feulvarch E (2015) 3D stationary simulation of a turning operation with an Eulerian approach. Appl Therm Eng 76:134–146. https://doi.org/10.1016/j.applthermaleng.2014.11.006

    Article  Google Scholar 

  6. Madhavan V, Adibi-Sedeh A (2005) Understanding of finite element analysis results under the framework of Oxley’s machining model. Mach Sci Technol 9:345–368. https://doi.org/10.1080/10910340500196587

    Article  Google Scholar 

  7. Meng L, Atli M, Khan A, Su Y, Fang C, Zhang H, He N (2019) Prediction of residual stresses generated by machining Ti6Al4V alloy based on the combination of the ALE approach and indentation model. J Braz Soc Mech Sci Eng 41:1–15. https://doi.org/10.1007/s40430-019-1914-5

    Article  Google Scholar 

  8. Ducobu F, Rivière-Lorphèvre E, Filippi E (2014) Numerical contribution to the comprehension of saw-toothed Ti6Al4V chip formation in orthogonal cutting. Int J Mech Sci 81:77–87. https://doi.org/10.1016/j.ijmecsci.2014.02.017

    Article  Google Scholar 

  9. Clavier F, Valiorgue F, Courbon C, Dumas M, Rech J, Van Robaeys A, Lefebvre F, Brosse A, Karaouni H (2020) Impact of cutting tool wear on residual stresses induced during turning of a 15–5 PH stainless steel. Procedia CIRP 87:107–112. https://doi.org/10.1016/j.procir.2020.02.074

    Article  Google Scholar 

  10. Ducobu F, Rivière-Lorphèvre E, Filippi E (2016) Application of the Coupled Eulerian-Lagrangian (CEL) method to the modeling of orthogonal cutting. Eur J Mech A-Solids 59:58–66. https://doi.org/10.1016/j.euromechsol.2016.03.008

    Article  MATH  Google Scholar 

  11. Liu Y, Agmell M, Xu D, Ahadi A, Stahl J, Zhou J (2020) Numerical contribution to segmented chip effect on residual stress distribution in orthogonal cutting of Inconel 718. Int J Adv Manuf Technol 109:993–1005. https://doi.org/10.1007/s00170-020-05702-2

    Article  Google Scholar 

  12. Javidikia M, Sadeghifar M, Songmene V, Jahazi M (2021) 3D FE modeling and experimental analysis of residual stresses and machining characteristics induced by dry, MQL, and wet turning of AA6061-T6. Mach Sci Technol 25:957–983. https://doi.org/10.1080/10910344.2021.1971709

    Article  Google Scholar 

  13. Sahu N, Andhare A (2019) Prediction of residual stress using RSM during turning of Ti6Al4V with the 3D FEM assist and experiments. SN Appl Sci 1:1–14. https://doi.org/10.1007/s42452-019-0809-5

    Article  Google Scholar 

  14. Liu G, Huang C, Su R, Özel T, Liu Y, Xu L (2019) 3D FEM simulation of the turning process of stainless steel 17–4PH with differently texturized cutting tools. Int J Mech Sci 155:417–429. https://doi.org/10.1016/j.ijmecsci.2019.03.016

    Article  Google Scholar 

  15. Tzotzis A, García-Hernández C, Huertas-Talón J, Kyratsis P (2020) Influence of the nose radius on the machining forces induced during AISI-4140 hard turning: a CAD-based and 3D FEM approach. Micromachines 11:798. https://doi.org/10.3390/mi11090798

    Article  Google Scholar 

  16. Attanasio A, Ceretti E, Giardini C (2009) 3D FE modelling of superficial residual stresses in turning operations. Mach Sci Technol 13:317–337. https://doi.org/10.1080/10910340903237806

    Article  Google Scholar 

  17. Arrazola P, Ozel T (2008) Numerical modelling of 3D hard turning using arbitrary Lagrangian Eulerian finite element method. Int J Mach Mach Mater 4:14–25. https://doi.org/10.1504/ijmmm.2008.020907

    Article  Google Scholar 

  18. Zhuang K, Zhou S, Zou L, Lin L, Liu Y, Weng J, Gao J (2022) Numerical investigation of sequential cuts residual stress considering tool edge radius in machining of AISI 304 stainless steel. Simul Model Pract Theory 118:102525. https://doi.org/10.1016/j.simpat.2022.102525

    Article  Google Scholar 

  19. Weng J, Liu Y, Zhuang K, Xu D, M’Saoubi R, Hrechuk A, Zhou J (2021) An analytical method for continuously predicting mechanics and residual stress in fillet surface turning. J Manuf Process 68:1860–1879. https://doi.org/10.1016/j.jmapro.2021.07.004

    Article  Google Scholar 

  20. Xu X, Outeiro J, Zhang J, Xu B, Zhao W, Astakhov V (2021) Machining simulation of Ti6Al4V using coupled Eulerian-Lagrangian approach and a constitutive model considering the state of stress. Simul Model Pract Theory 110:102312. https://doi.org/10.1016/j.simpat.2021.102312

    Article  Google Scholar 

  21. Yue Q, He Y, Li Y, Tian S (2022) Investigation on effects of single and multiple-pass strategies on residual stress in machining Ti-6Al-4V alloy. J Manuf Process 77:272–281. https://doi.org/10.1016/j.jmapro.2022.03.013

    Article  Google Scholar 

  22. Liu C, Guo Y (2000) Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer. Int J Mech Sci 42:1069–1086. https://doi.org/10.1016/S0020-7403(99)00042-9

    Article  MATH  Google Scholar 

  23. Zhang X, Huang X, Chen L, Leopold J, Ding H (2017) Effects of sequential cuts on white layer formation and retained austenite content in hard turning of AISI52100 steel. J Manuf Sci Eng Trans ASME 139:064502. https://doi.org/10.1115/1.4035125

    Article  Google Scholar 

  24. Liu Y, Xu D, Agmell M, Ahadi A, Stahl J, Zhou J (2021) Investigation on residual stress evolution in nickel-based alloy affected by multiple cutting operations. J Manuf Process 68:818–833. https://doi.org/10.1016/j.jmapro.2021.06.015

    Article  Google Scholar 

  25. Mondelin A, Valiorgue F, Rech J, Coret M (2021) 3D hybrid numerical model of residual stresses: numerical-sensitivity to cutting parameters when turning 15–5PH stainless steel. J Manuf Mater Process 5:70. https://doi.org/10.3390/jmmp5030070

    Article  Google Scholar 

  26. Xu B, Zhang J, Liu H, Xu X, Zhao W (2021) Serrated chip formation induced periodic distribution of morphological and physical characteristics in machined surface during high-speed machining of Ti6Al4V. J Manuf Sci Eng Trans ASME 143:101006. https://doi.org/10.1115/1.4050760

    Article  Google Scholar 

  27. Denkena B, Biermann D (2014) Cutting edge geometries. CIRP Ann 63:631–653. https://doi.org/10.1016/j.cirp.2014.05.009

    Article  Google Scholar 

  28. Matsumoto Y, Da-Chun H (1987) Workpiece temperature rise during the cutting of AISI 4340 steel. Wear 116:309–317. https://doi.org/10.1016/0043-1648(87)90179-7

    Article  Google Scholar 

  29. Lin Z, Lee B (1995) An investigation of the residual stress of a machined workpiece considering tool flank wear. J Mater Process Technol 51:1–24. https://doi.org/10.1016/0924-0136(94)01322-R

    Article  Google Scholar 

  30. Johnson G, Cook W (1983) A constitutive model and data for materials subjected to large strains, high strain rates, and high temperatures. Proc 7th Inf Sympo Ballistics 21:541–547

    Google Scholar 

  31. Korkmaz H, Toros S, Halkaci M, Halkaci H (2018) Investigation of hydro-piercing method for stainless steels by finite element method. MATEC Web Conf 220:01003. https://doi.org/10.1051/matecconf/201822001003

    Article  Google Scholar 

  32. Çaydaş U, Ekici S (2012) Support vector machines models for surface roughness prediction in CNC turning of AISI 304 austenitic stainless steel. J Intell Manuf 23:639–650. https://doi.org/10.1007/s10845-010-0415-2

    Article  Google Scholar 

  33. Zhang W, Zhuang K, Pu D (2020) A novel finite element investigation of cutting force in orthogonal cutting considering plough mechanism with rounded edge tool. Int J Adv Manuf Technol 108:3323–3334. https://doi.org/10.1007/s00170-020-05547-9

    Article  Google Scholar 

  34. Johnson G, Cook W (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48. https://doi.org/10.1016/0013-7944(85)90052-9

    Article  Google Scholar 

  35. Zorev N (1963) Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting. Int Res Prod Eng 49:143–152

    Google Scholar 

  36. Wu D, Liu C (1985) An analytical model of cutting dynamics. Part 1: Model building. ASME J Eng Ind 107:107–111. https://doi.org/10.1115/1.3185972

    Article  Google Scholar 

  37. Saka N, Eleiche A, Suh N (1977) Wear of metals at high sliding speeds. Wear 44:109–125. https://doi.org/10.1016/0043-1648(77)90089-8

    Article  Google Scholar 

  38. Agmell M, Ahadi A, Gutnichenko O, Ståhl J (2017) The influence of tool micro-geometry on stress distribution in turning operations of AISI 4140 by FE analysis. Int J Adv Manuf Technol 89:3109–3122. https://doi.org/10.1007/s00170-016-9296-7

    Article  Google Scholar 

  39. Liu Y, Xu D, Agmell M, Saoubi R, Ahadi A, Stahl J, Zhou J (2021) Numerical and experimental investigation of tool geometry effect on residual stresses in orthogonal machining of Inconel 718. Simul Model Pract Theory 106:102187. https://doi.org/10.1016/j.simpat.2020.102187

    Article  Google Scholar 

  40. Nasr M (2015) Effects of sequential cuts on residual stresses when orthogonal cutting steel AISI 1045. Procedia CIRP 31:118–123. https://doi.org/10.1016/j.procir.2015.03.032

    Article  Google Scholar 

Download references

Funding

This work is partially supported by the Guangdong Major Project of Basic and Applied Basic Research (2021B0301030001), National Natural Science Foundation of China (No. 52175482), and Alexander von Humboldt (AvH) Foundation.

Author information

Authors and Affiliations

  1. Chaozhou Branch of Chemistry and Chemical Engineering Guangdong Laboratory, Guangzhou, 521000, China

    Jian Weng, Shengqiang Zhou & Kejia Zhuang

  2. Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Jian Weng & Kejia Zhuang

  3. Institute of Machining Technology (ISF), TU Dortmund University, 44227, Dortmund, Germany

    Jian Weng & Yuhua Zhang

  4. China National South Aviation Industry Co., Ltd, Zhuzhou, 412000, China

    Yang Liu

  5. Division of Production and Materials Engineering, Lund University, 22100, Lund, Sweden

    Kejia Zhuang

Authors
  1. Jian Weng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shengqiang Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yuhua Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yang Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Kejia Zhuang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the study conception and design. Jian Weng: conceptualization, methodology, reviewing, and editing; Shengqiang Zhou: software, data curation, writing original draft; Yuhua Zhang: resources, reviewing; Yang Liu: methodology, reviewing; Kejia Zhuang: supervision, funding acquisition.

Corresponding author

Correspondence to Kejia Zhuang.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

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

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Weng, J., Zhou, S., Zhang, Y. et al. Numerical and experimental investigations on residual stress evolution of multiple sequential cuts in turning. Int J Adv Manuf Technol 129, 755–770 (2023). https://doi.org/10.1007/s00170-023-12311-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12311-2

Keywords

Search

Navigation