Physics-based modelling and validation of dynamically varying thermal and mechanical residual stress fields in finish machining of aerospace alloys

While the physics of chip formation have been widely studied, there remains a need for greater qualitative and quantitative understanding of the way thermal and mechanical loads, and particularly their dynamic variability across length and time scales affect both the magnitude and variability of machining-induced residual stress (MIRS). This paper leverages an advanced in-situ characterization technique along with a physics-based process model to accurately and quickly predict key MIRS variables for aerospace alloys Inconel 718 and Ti-6Al4V. Our analysis clearly shows opportunities for digitally enabled predictability of engineered surface integrity to evaluate the fatigue performance of aerospace alloys more effectively.