Effect Residual Stress on Material Hardness by Finite Element Simulation during the Process of High Speed Cutting

Abstract

Residual stresses induced during the process of high speed cutting are very critical due to safety and corrosion resistance. Based on the nonlinear finite element code DEFORM, thermodynamic couple model of residual stress was built. Effect distribution of residual stresses on three different materials physical properties of hardness are analyzed by using the finite element model during the process of high speed cutting. The results show that metal material hardness is the key factors to residual stress. When materials’ hardness is higher, residual tensile stress is easy to form on the machined surface due to high cutting temperature, such as hardened steel SKD11(HRC=62). To lower hardness material, residual compressive stress is generated on the machined surface for plastic deformation, such as softer materials 7075Al (HRC=23).