Abstract
Service performance of components such as fatigue life are dramatically influenced by the machined surface and subsurface residual stresses. This paper aims at achieving a better understanding of the influence of cutting edge microgeometry on machined surface residual stresses during orthogonal dry cutting of Inconel 718. Numerical and experimental investigations have been conducted in this research. The cutting edge microgeometry factors of average cutting edge radius , form-factor K, and chamfer were investigated. An increasing trend for the magnitudes of both tensile and compressive residual stresses was observed by using larger or introducing a chamfer on the cutting edges. The ploughing depth has been predicted based on the stagnation zone. The increase of ploughing depth means that more material was ironed on the workpiece subsurface, which resulted in an increase in the compressive residual stress. The thermal loads were leading factors that affected the surface tensile residual stress. For the unsymmetrical honed cutting edge with K = 2, the friction between tool and workpiece and tensile residual stress tended to be high, while for the unsymmetrical honed cutting edge with K = 0.5, the high ploughing depth led to a higher compressive residual stress. This paper provides guidance for regulating machine-induced residual stress by edge preparation.
Highlights
More research attention has been paid to high performance and high process reliability in production due to the increasing demand for difficult-to-machine materials such as nickel alloys in the aerospace industry [1,2]
Aero-engine components such as turbine disks and shafts are subjected to huge and complex alternating loads during service conditions. Their service performance depends on their surface low cycle fatigue life, which is mainly influenced by the machine-induced surface residual stresses [3]
The tensile residual stress tends to engender crack initiation and propagation, which contributes to the diminution of fatigue life, whereas the compressive residual stress is conducive to fatigue life by suppressing crack propagation
Summary
More research attention has been paid to high performance and high process reliability in production due to the increasing demand for difficult-to-machine materials such as nickel alloys in the aerospace industry [1,2]. Aero-engine components such as turbine disks and shafts are subjected to huge and complex alternating loads during service conditions. Their service performance depends on their surface low cycle fatigue life, which is mainly influenced by the machine-induced surface residual stresses [3]. The residual stresses impose an additional stress state on the surface of machined components during operation. The tensile residual stress tends to engender crack initiation and propagation, which contributes to the diminution of fatigue life, whereas the compressive residual stress is conducive to fatigue life by suppressing crack propagation. Regulating the final stress condition during the cutting process is of paramount importance
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