Prediction model of surface residual stress within a machined surface by combining two orthogonal plane models |
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| Authors: | Hiroyuki Sasahara Toshiyuki Obikawa Takahiro Shirakashi |
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| Affiliation: | a Department of Mechanical Systems Engineering, Tokyo University of Agriculture and Technology, 2-24-16 Nakacho, Koganei, Tokyo 184-8588, Japan;b Department of Mechanical and Control Engineering, Tokyo Institute of Technology, 2-12-1 Ookayama, Meguro-ku, Tokyo 152-8552, Japan;c Department of Precision Machinery Engineering, Tokyo Denki University, 2-2 Kanda Nishikicho, Chiyoda-ku, Tokyo 101-8457, Japan |
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| Abstract: | The variation of surface residual stress within a machined surface layer caused by face turning was studied. The size of the tool’s corner radius and the feed rate affect residual stress. A process model using the finite element method is proposed and the mechanical effects of the corner radius and feed rate on a machined surface were discussed. When a tool with a small corner radius is used, surface residual stress perpendicular to the cutting direction becomes compression stress. As well, surface residual stress changes from tension to compression as the feed rate decreases. The process model consists of an orthogonal cutting simulation and an indentation-like simulation of a corner radius into a work piece surface. The simulated results show quantitative agreement with the residual stress measured experimentally. The integrity of the machined surface will be controlled more efficiently if the cutting conditions during finishing are determined with the proper consideration of the surface generating process. |
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| Keywords: | Author Keywords: Cutting Residual stress Machined surface Face turning Corner radius of tool FEM |
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