Residual Stresses during Hard Turning of AISI 52100 Steel: Numerical Modelling with Experimental Validation

Abstract

Residual stresses induced by machining processes are a consequence of thermo-mechanical and microstructural phenomena generated during the machining operation. In this study, a numerical approach has been developed to predict the near surface residual stresses resulting from turning of AISI 52100 alloys steel and validated by experimental results. Effect of cutting parameters, namely cutting speed and depth of cut on induced residual stresses in machined surface was investigated by modelling using ABAQUS/CAE 14.0 software. Explicit Dynamics time integration with adaptive meshing finite element method is employed to simulate the 2D model. The Johnson-Cook material model is used to describe the work material behaviour to simulate high speed machining with an orthogonal cutting. And also for experimental analysis X-Ray diffraction method is considered. While study residual stresses at different cutting speed, feed rate, and depth of cut is studied. As a conclusion we can say that cutting speed and feed rate plays major role as compared to depth of cut. And as cutting speed or feed rate increases tensile residual stresses increases.