Coupled Eulerian-Lagrangian model for residual stress prediction in orthogonal cutting of Waspaloy

Abstract

Residual stress is one of the most critical factors of machined surface integrity, which directly determines corrosion resistance and fatigue life of components. Therefore, it is necessary to accurately predict the machining-induced residual stress, especially for critical aerospace parts. In this paper, a finite element model based on the Coupled Eulerian-Lagrangian method is employed to predict the residual stress in orthogonal cutting of Waspaloy material under different cutting conditions. The depth profiles of residual stress along the cutting speed direction are determined using the X-ray diffraction and electropolishing techniques. The results show tensile residual stresses at the cutting speeds of 64 m/min and 86 m/min with 100 microns uncut chip thickness. The depth at the machined surface influenced by the residual stress is identified and compared from both simulations and experiments. The simulated cutting forces and residual stress distributions from the finite element model are compared with the experimental results to validate the model. In addition, the microstructure property at the machined surface is examined to determine the depth of plastic deformation layers. White layers are identified at the higher cutting speed, and it is shown that the formation of white layers is directly related to the location of the peak tensile residual stress.