Residual Stresses in High Speed Turning of Thin-Walled Cylindrical Workpieces

Abstract

Residual stress induced in cutting processes substantially impacts adversely on functional part performance and distortion, especially when thin-walled workpieces are machined. For this reason, basic research focuses on the correlation between a specific high-speed turning configuration and the occurrence of residual stress and the amount of resulting distortion. The presented experiments in high-speed turning of thin-walled AISI 52100 (100Cr6) steel workpieces show, that residual stress distribution in the surface layer moves toward compressive stress as cutting speed increases while feed and lower wall-thickness decrease. Indications were also, that increasing cutting speed leads to higher distortion. To evaluate residual stress potential in shape deviation, the so-called source forceF’sourcewas calculated by numerically integrating the residual stress depth profile.