Abstract
A numerically developed residual stress distribution model during turning Ti6Al4V alloy with an Internally Cooled Tool (ICT) has been validated experimentally. The effect of inlet coolant pressure on cutting forces and temperature has been predicted. The predicted and measured values for forces and temperature lies in 10-20%. The residual stress at the surface and subsurface layer has been validated with XRD technique. It is found to be well suited in predicting the trend for residual stress of Ti6Al4V with ICT. Maximum residual stress in cutting direction is -308 MPa and -319 MPa for laminar and turbulent flow respectively.
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