Abstract
In this paper, the residual stresses on workpiece surface after cutting operations are studied by means of 3D finite element method (FEM) simulations and the results are compared with the experiments. In particular, the effects of feed rate and tool nose radius on the final workpiece residual stresses when turning AISI 1045 steel bars were analyzed; two different approaches were utilized for the simulative models. In the first approach incremental Lagrangian and Eulerian solvers were coupled to reach both mechanical and thermal steady state conditions performing a single cutting pass, while the second approach consisted of an incremental Lagrangian simulation in which consecutive turning passes were considered in order to reach mechanical and thermal steady state. The simulation results were finally compared with the experimental ones: the agreement between them is satisfactory even if the numerical errors are, in some cases, remarkable.
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