Numerical and experimental analysis of residual stress and plastic strain distributions in machined stainless steel

• Published in: International journal of mechanical sciences Vol. 64; no. 1; pp. 82 - 93
• Main Authors: Ben Moussa, N., Sidhom, H., Braham, C.
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.11.2012; Elsevier
• Subjects: Austenitic stainless steels; Computer simulation; Engineering Sciences; Heat resistant steels; Machining; Materials; Mathematical models; Numerical simulation; Plastic deformation; Plastic strain; Residual stress; Stainless steels; Strain; Surface properties; Surface properties; Numerical simulation; Residual stress; Plastic strain; Machining
• ISSN: 0020-7403; 1879-2162
• DOI: 10.1016/j.ijmecsci.2012.07.011

In this study, a numerical approach has been developed to predict the near surface residual stresses and plastic strain resulting from turning in orthogonal cutting configuration. This approach is based on the Arbitrary Lagrangian–Eulerian (ALE) formulation using the commercial finite element code Abaqus–Explicit. The coefficients of the used material behavior law and friction model required for the simulation are identified experimentally in this study. The simulated results are validated by experiments carried out on AISI 316L stainless steel. Using this method, the effect of the depth of cut (Doc) and the cutting speed (Vc) on the surface properties has been established. The simulated residual stress gradient resulting from machining has been experimentally validated by X-ray diffraction measurements. The simulated plastic strain gradient has been validated by an experimental microhardness–strain relationship established in this study. ► We developed a numerical approach to calculate residual stress generated by machining. ► An experimental microhardness–strain relationship is established. ► This relationship is used to calibrate the predictive approach. ► Numerical results were validated by residual stress X-ray diffraction measurements. ► Effects of process conditions on residual stress and strain profiles were identified.