Abstract
Finite element (FE) models have been developed to predict average surface residual stresses during hard turning of AISI 4340 steel with self-propelled rotary tools (SPRT). Three dimensional chip formation analysis have been carried out using coupled temperature displacement analysis. In the next step, the workpiece is unloaded and allowed to cool till the attainment of room temperature using convective heat transfer model. The residual stresses in the cutting direction obtained using the FE models are validated using experimentally measured ones using X-ray diffraction technique. A good agreement has been found between the predicted and experimental values and the average errors are around 11–12%. In addition, residual stresses obtained with the fixed tool are also evaluated and compared with SPRT. The effects of cutting speed and feed rate on residual stresses using SPRT have also been analyzed and discussed.
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