Empirical modeling of residual stress profiles in Ti6Al4V after face-milling

Abstract

Titanium represents a large part of critical structural and engine components on aircrafts. Surface residual stresses generated during machining are highly relevant regarding the fatigue behavior of these components. Nevertheless, the complex nature of the residual stress generation process prevents considering them during part and machining process design phases. In this work, an empirical model based on an exponential decay cosine function for surface residual stresses prediction is presented. Modeling data was obtained by X-ray diffraction from face-milled surfaces on Ti6Al4V. The model was validated with further experimental data, showing its capability to provide a powerful residual stress prediction tool.