Prediction of residual stress in the process of turning high strength alloy steel by innovative coated carbide microgroove tools

Abstract

Residual stress (RS) of machined surface is one of essential factors affecting the service performance of mechanical structures and parts. By a combination of cutting experiment, theoretical analysis, and finite element analysis, this paper focuses on the radial distribution of RS of machined surfaces of a coated carbide microgroove turning tool (CCMTT), firstly, in the turning of the high strength alloy steel. The effect of cutting parameters on the radial distribution of RS of machined surfaces produced by the CCMTT is further researched. Finally, the prediction model of RS produced by the CCMTT is established and verified. Research results show that the cutting experiments and FE simulation both have the same variation tendency of RS and are validated well each other. The microgroove on the rake face of the CCMT is beneficial to increase the thickness and the maximum value of residual compressive stress of surface material. The coefficient of multiple correlation of the forecasting model of surface residual stress (SRS) machined by the CCMTT reaches 97.4%, which illustrates that the model has relatively high reliability.