Hostname: page-component-78c5997874-94fs2 Total loading time: 0 Render date: 2024-11-15T09:20:32.720Z Has data issue: false hasContentIssue false
  • English
  • Français

Finite element modeling of residual stress profile patterns in hard turning

Published online by Cambridge University Press:  06 March 2012

Y. B. Guo  and
S. Anurag
Y. B. Guo
Affiliation:
Department of Mechanical Engineering, University of Alabama, Tuscaloosa, Alabama 35487, USA
S. Anurag
Affiliation:
Department of Mechanical Engineering, University of Alabama, Tuscaloosa, Alabama 35487, USA
Get access Rights & Permissions [Opens in a new window]

Abstract

Hard turning, i.e., turning hardened steels, may produce the unique “hook” shaped residual stress (RS) profile characterized by surface compressive RS and subsurface maximum compressive RS. However, the formation mechanism of the unique RS profile is not yet known. In this study, a novel hybrid finite element modeling approach based on thermal-mechanical coupling and internal state variable plasticity model has been developed to predict the unique RS profile patterns by hard turning AISI 52100 steel (62 HRc). The most important controlling factor for the unique characteristics of residual stress profiles has been identified. The transition of maximum residual stress at the surface to the subsurface has been recovered by controlling the plowed depth. The predicted characteristics of residual stress profiles favorably agree with the measured ones. In addition, friction coefficient only affects the magnitude of surface residual stress but not the basic shape of residual stress profiles.

Keywords

residual stresshard turningmodelingfinite element analysis
Type
Methods For Residual Stress Analysis
Information
Powder Diffraction , Volume 24 , Supplement S1 , June 2009 , pp. S22 - S25
Copyright
Copyright © Cambridge University Press 2009

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

Abrao, A. M. and Aspinwall, D. K. (1996). “The surface integrity of turned and ground hardened bearing steel,” WearWEARCJ 196, 279–284.10.1016/0043-1648(96)06927-XCrossRefGoogle Scholar
Bammann, D. J., Chiesa, M. L., and Johnson, G. C. (1996), edited by T. Tatsumi, E. Watanabe, and T. Kambe, “Modeling large deformation and failure in manufacturing processes,” Theor. App. Mech. 359–376.Google Scholar
Brinksmeier, E., Cammett, J. T., Koenig, W., Leskovar, P., Peters, J., and Toenshoff, H. K. (1982). “Residual stresses measurement and causes in machining processes,” CIRP Ann.CIRAAT 31, 491–510.10.1016/S0007-8506(07)60172-3Google Scholar
Byrne, G., Dornfeld, D., and Denkena, B. (2003). “Advancing cutting technology,” CIRP Ann.CIRAAT 52, 483–507.10.1016/S0007-8506(07)60200-5CrossRefGoogle Scholar
Guo, Y. B. and Liu, C. R. (2002). “FEM analysis of residual stress distribution and formation mechanisms in machining,” Int. J. of Mach. Sci. Tech. 6, 21–41.10.1081/MST-120003183CrossRefGoogle Scholar
Guo, Y. B. and Wen, Q. (2005). “A hybrid modeling approach to investigate chip morphology transition with the stagnation effect by cutting edge geometry,” Trans. NAMRI/SMEZZZZZZ 33, 469–476.Google Scholar
Guo, Y. B., Wen, Q., and Woodbury, K. A. (2006). “Dynamic material behavior modeling using internal state variable plasticity and its application in hard machining simulations,” ASME J. Manuf. Sci. Eng.JMSEFK 128, 749–759.10.1115/1.2193549CrossRefGoogle Scholar
Hashimoto, F., Guo, Y. B., and Warren, A. W. (2006). “Surface integrity difference between hard turned and ground surfaces and its impact on fatigue life,” CIRP Ann.CIRAAT 55, 81–84.10.1016/S0007-8506(07)60371-0Google Scholar
HKS, Inc. (2007). ABAQUS/Explicit User’s Manual, Ver. 6.6 (HKS, Providence, RI).Google Scholar
Klocke, F., Brinksmeier, E., and Weinert, K. (2005). “Capability profiles of hard cutting and grinding processes,” CIRP Ann.CIRAAT 54, 22–45.10.1016/S0007-8506(07)60018-3CrossRefGoogle Scholar
Konig, W., Klinger, M., and Link, R. (1990). “Machining hard materials with geometrically defined cutting edges-field of applications and limitations,” CIRP Ann.CIRAAT 39, 61–64.10.1016/S0007-8506(07)61003-8CrossRefGoogle Scholar
Malkin, S. and Guo, C. (2007). “Thermal anaysis of grinding,” CIRP Ann.CIRAAT 56, 760–782.10.1016/j.cirp.2007.10.005CrossRefGoogle Scholar
Matsumoto, Y., Barash, M. M., and Liu, C. R. (1986). “Effect of hardness on the surface integrity of AISI 4340 steel,” J. Eng. Ind.JEFIA8 180, 169–175.Google Scholar
Matsumoto, Y., Hashimoto, F., and Lahoti, G. (1999). “Surface integrity generated by precision hard turning,” CIRP Ann.CIRAAT 48, 59–62.10.1016/S0007-8506(07)63131-XGoogle Scholar
Rech, J., Kermouche, G., Grzesik, W., Garcia-Rosales, C., Khellouki, A., and Garcia-Navas, V. (2008). “Characterization and modeling of the residual stresses induced by belt finishing on a AISI52100 hardened steel,” J. Mater. Process. Technol.JMPTEF 208, 187–195.10.1016/j.jmatprotec.2007.12.133Google Scholar
Schwach, D. W. and Guo, Y. B. (2006). “A fundamental study on the impact of surface integrity by hard turning on rolling contact fatigue,” Int. J. FatigueIJFADB 28, 1838–1844.10.1016/j.ijfatigue.2005.12.002Google Scholar
Töenshoff, H. K., Wobker, H. G., and Brandt, D. (1995). “Hard turning-influences on the workpiece properties,” Trans. NAMRI/SMEZZZZZZ 23, 215–220.Google Scholar
Valiorgue, F., Rech, J., Hamdi, H., Gilles, P., and Bergheau, J. M. (2007). “A new approach for the modeling of residual stresses induced by turning of 316L,” J. Mater. Process. Technol.JMPTEF 191, 270–273.10.1016/j.jmatprotec.2007.03.021Google Scholar