Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius

K. C. Ee, O. W. Dillon, I. S. Jawahir

Research output: Contribution to journalArticlepeer-review

155 Scopus citations

Abstract

A thermal elastic-viscoplastic finite element model is used to evaluate the residual stresses remaining in a machined component. An improvement in the accuracy of the predicted residual stresses is obtained by: (a) using a modified Johnson-Cook material model that is augmented by a linearly elastic component to describe the material behavior as non-Newtonian fluid; (b) using a remeshing scheme to simulate the material flow in the vicinity of the rounded cutting tool edge without the use of a separation criterion; (c) properly accounting for the unloading path, and (d) considering the thermomechanical coupling effect on deformation. Case studies are performed to study the influence of sequential cuts, cutting conditions, etc., on the residual stresses induced by orthogonal machining.

Original languageEnglish
Pages (from-to)1611-1628
Number of pages18
JournalInternational Journal of Mechanical Sciences
Volume47
Issue number10
DOIs
StatePublished - Oct 2005

Keywords

  • Finite element method
  • Machining
  • Residual stresses

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering
  • Aerospace Engineering
  • Ocean Engineering
  • Applied Mathematics
  • General Materials Science
  • Civil and Structural Engineering

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