Investigation on residual stress evolution in nickel-based alloy affected by multiple cutting operations
(2021) In Journal of Manufacturing Processes 68. p.818-833- Abstract
Machining-induced residual stresses in a part can significantly influence its performance and service time. It is common that the final surface of the part is produced after multiple cuts in the machining process. In multiple cuts, the previous cuts could often generate accumulated strain/stress and temperature on the part surface. These accumulated strain/stress and temperature will be brought to the subsequent cut or final cut and continuously affect the cutting forces, process temperatures, deformation zones, etc. in subsequent cut, and eventually affect the final residual stresses on the part. This paper reports on a joint experimental and numerical investigation to explore the influence of previous cuts on surface residual stresses... (More)
Machining-induced residual stresses in a part can significantly influence its performance and service time. It is common that the final surface of the part is produced after multiple cuts in the machining process. In multiple cuts, the previous cuts could often generate accumulated strain/stress and temperature on the part surface. These accumulated strain/stress and temperature will be brought to the subsequent cut or final cut and continuously affect the cutting forces, process temperatures, deformation zones, etc. in subsequent cut, and eventually affect the final residual stresses on the part. This paper reports on a joint experimental and numerical investigation to explore the influence of previous cuts on surface residual stresses with consideration of cutting parameters, cutting procedure, and tool geometries in multiple cut of Inconel 718 alloy. Coupled Eulerian and Lagrangian (CEL) formulation is used in a two/three-cuts numerical model. The loading cycles of the selected material nodes are characterised based on isotropic constitutive model (Johnson-Cook model) to analyse the underlying mechanism of residual stress evolution during cutting sequences. The results show that accumulated stress/strain induced by previous cuts lead to a more curled chip morphology, a slight decrease in cutting force and a slight increase in feed force in the subsequent cut. An increased magnitude and depth of compressive residual stresses in the finished workpiece are generated owing to the influence of previous cuts, and this is more obvious when the previous cut is implemented at a larger uncut chip thickness, using a more negative rake angle or a larger edge radius tool. The residual stress level might be controlled by optimizing the previous cuts to get the desired surface integrity.
(Less)
- author
- Liu, Yang LU ; Xu, Dongdong ; Agmell, Mathias LU ; Ahadi, Aylin LU ; Stahl, Jan Eric LU and Zhou, Jinming LU
- organization
- publishing date
- 2021-08
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Coupled Eulerian and Lagrangian (CEL), Inconel718, Machining, Multiple cuts, Residual stress
- in
- Journal of Manufacturing Processes
- volume
- 68
- pages
- 16 pages
- publisher
- Elsevier
- external identifiers
-
- scopus:85108991804
- ISSN
- 1526-6125
- DOI
- 10.1016/j.jmapro.2021.06.015
- language
- English
- LU publication?
- yes
- additional info
- Funding Information: Authors would like to thank Mr. Per Alm and Dr. Rachid M'saoubi for their technical support in the preparation of the cutting experiment at Seco Tools. The acknowledgement especially extends to Dr. Rachid M'saoubi for the help with valuable feedback and productive discussions. One of the authors (Y. Liu) appreciates the financial support from China Scholarship Council (No. 201706130144 ). Publisher Copyright: © 2021 The Author(s) Copyright: Copyright 2021 Elsevier B.V., All rights reserved.
- id
- c9711c9d-26e5-4aed-a07b-bd390241d7c7
- date added to LUP
- 2021-08-02 17:54:55
- date last changed
- 2023-11-08 16:44:22
@article{c9711c9d-26e5-4aed-a07b-bd390241d7c7,
abstract = {{<p>Machining-induced residual stresses in a part can significantly influence its performance and service time. It is common that the final surface of the part is produced after multiple cuts in the machining process. In multiple cuts, the previous cuts could often generate accumulated strain/stress and temperature on the part surface. These accumulated strain/stress and temperature will be brought to the subsequent cut or final cut and continuously affect the cutting forces, process temperatures, deformation zones, etc. in subsequent cut, and eventually affect the final residual stresses on the part. This paper reports on a joint experimental and numerical investigation to explore the influence of previous cuts on surface residual stresses with consideration of cutting parameters, cutting procedure, and tool geometries in multiple cut of Inconel 718 alloy. Coupled Eulerian and Lagrangian (CEL) formulation is used in a two/three-cuts numerical model. The loading cycles of the selected material nodes are characterised based on isotropic constitutive model (Johnson-Cook model) to analyse the underlying mechanism of residual stress evolution during cutting sequences. The results show that accumulated stress/strain induced by previous cuts lead to a more curled chip morphology, a slight decrease in cutting force and a slight increase in feed force in the subsequent cut. An increased magnitude and depth of compressive residual stresses in the finished workpiece are generated owing to the influence of previous cuts, and this is more obvious when the previous cut is implemented at a larger uncut chip thickness, using a more negative rake angle or a larger edge radius tool. The residual stress level might be controlled by optimizing the previous cuts to get the desired surface integrity.</p>}},
author = {{Liu, Yang and Xu, Dongdong and Agmell, Mathias and Ahadi, Aylin and Stahl, Jan Eric and Zhou, Jinming}},
issn = {{1526-6125}},
keywords = {{Coupled Eulerian and Lagrangian (CEL); Inconel718; Machining; Multiple cuts; Residual stress}},
language = {{eng}},
pages = {{818--833}},
publisher = {{Elsevier}},
series = {{Journal of Manufacturing Processes}},
title = {{Investigation on residual stress evolution in nickel-based alloy affected by multiple cutting operations}},
url = {{http://dx.doi.org/10.1016/j.jmapro.2021.06.015}},
doi = {{10.1016/j.jmapro.2021.06.015}},
volume = {{68}},
year = {{2021}},
}