Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Abstract

AbstractThe application of finite element models is a promising method for ensuring part quality during machining to accurately predict induced residual stresses and cutting forces. The present study applied Analysis System software to formulate a 3D model to predict induced residual stress and forces for AISI 1020 alloy. Taguchi method was applied in the design of the experiment with three levels and three factors selected: Cutting speed, feed rate and depth of cut. For validation, stresses are measured using an x‐ray diffractometer from the surface to a depth of 0.6 mm in steps of 0.2 mm. The cutting forces are determined using a force dynamometer. Simulation results showed that cutting speed, feed rate and depth of cut contributed 94.76 %, 0.048 %, and 0.11 % respectively. The predictive model equations were statistically significant with a p‐value of <0.005. The average induced residual stress on the superficial layer from the experiment and simulation were −367.7 MPa and −365.6 MPa respectively. The average residual stresses obtained at depths of 0.2 mm, 0.4 mm, and 0.6 mm were −260 MPa, −233 MPa, and −211 MPa, respectively. The proposed model offers a potential solution to reducing the costs of experimental methods.