Modeling and analysis of residual stress in dynamic orthogonal cutting

Abstract

Abstract This work develops a predictive model to explore the influence of vibration on residual stress during orthogonal cutting process. The first part involves the design of a low-speed dynamic cutting setup and a measuring device of chip thickness and cutting forces. The second part established an analytical model to calculate the mechanical load in the primary shear zone and tertiary shear zone by using the experimental measurements. Finally, the equivalent moving mechanical load is applied to the workpiece based on the birth-death element method to predict the residual stress without the need to consider the tool-workpiece contact. The simulations show that the vibration has a significant effect on residual stress, and experimental validations will be conducted in the next stage.