The prediction of the turned machining induced residual stresses in Ti6Al4V: A Critical Surface Integrity Descriptor

• Published in: MATEC Web of Conferences Vol. 347; p. 37
• Main Authors: Styger, Gary, Laubscher, Rudolph F
• Format: Journal Article Conference Proceeding
• Language: English
• Published: Les Ulis EDP Sciences 2021
• Subjects: Corrosion fatigue; Cutting parameters; Cutting speed; Feed rate; Finite element method; Integrity; Machining; Process parameters; Rake angle; Residual stress; Surface roughness; Titanium alloys; Titanium base alloys
• DOI: 10.1051/matecconf/202134700037
• ISSN: 2261-236X; 2274-7214

The surface integrity of a turned machined surface is an essential indicator of the fatigue and corrosion performance of a component. A critical descriptor of this property is the residual stress, both on the surface and subsurface of a part. However, experimental determination of vital surface integrity parameters such as surface roughness, hardness, affected microstructure, and residual stresses is costly, time consuming, and involves the destruction of the part. Therefore, prediction of these parameters, such as residual stress versus depth, would be of great value and could aid in the correct machining parameters (cutting speed, feed rate, edge tool radius, rake angle, coolant) for the desired part performance. A study was initiated to determine the influence of a worn tool and multiple cuts on a wide range of cutting speeds on residual stresses induced by machining an outside-turned bar of Ti6Al4V titanium alloy. Thus, a project was initiated to develop a non-linear finite element model to predict the residual stresses thus developed due to the machining manufacturing process.