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Analytical modeling of milling residual stress under different tool wear conditions

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Abstract

The machining residual stress generated on the surface of the machined parts during machining has a crucial influence on the machining accuracy, fatigue strength, and corrosion resistance of the parts. Tool wear will aggravate the tool-work friction, and the thermal and mechanical load will change significantly, affecting the residual stress distribution. The distribution of 3D oblique cutting mechanical stress and thermal stress during tool wear is predicted by analyzing the 3D contact state of quick oblique cutting. The incremental thermal-elastic–plastic method is used for stress loading, and the 3D relaxation method is used for stress release to obtain residual stress. An analytical residual stress model considering tool wear is proposed to predict the residual stress distribution in milling, while aluminum alloy 7075-T6 is used as the workpiece in the case study. The results show that with the increase of tool wear, the residual stress of machined surface transfers from compressive stress to tensile stress, the value of sub-surface residual compressive stress increases the peak value of compressive stress moves more resounding, and the thickness of residual stress layer increases significantly. The average error between the predicted and experimental values is about 23.3%, which proves the model’s validity and provides a new idea for controlling the distribution of machining residual stress.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This work was supported by National Natural Science Foundation of China, (Grant No.52175393).

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Authors and Affiliations

  1. Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, China

    Junhui Lu, Caixu Yue, Zhitao Chen, Xianli Liu & Ming Li

  2. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, USA

    Steven Y. Liang

Authors
  1. Junhui Lu
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  2. Caixu Yue
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  3. Zhitao Chen
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  4. Xianli Liu
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  5. Ming Li
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  6. Steven Y. Liang
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Contributions

Junhui Lu: methodology, investigation, experiments, writing—original draft, writing—review and editing, visualization; Caixu Yue: project administration, investigation, conceptualization, supervision; Zhitao Chen: conceptualization, supervision; Xianli Liu: project administration, validation, supervision; Ming Li: supervision, Validation; Steven Y. Liang: writing—review and editing, supervision, validation.

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Correspondence to Caixu Yue.

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The content studied in this article belongs to the field of metal processing, does not involve humans and animals. This article strictly follows the accepted principles of ethical and professional conduct.

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Lu, J., Yue, C., Chen, Z. et al. Analytical modeling of milling residual stress under different tool wear conditions. Int J Adv Manuf Technol 127, 4253–4269 (2023). https://doi.org/10.1007/s00170-023-11715-4

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  • DOI: https://doi.org/10.1007/s00170-023-11715-4

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