Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer

A thermo-elastic-viscoplastic model using explicit finite element code Abaq us was developed to investigate the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer. Chip formation, cutting forces and temperature were also examined in the sequential cuts. The affe cted layer from the first cut slightly changes the chip thickness, cutting forces, residual strain and temperature of the machined layer, but signific antly affects the residual stress distribution produced by the second cut. Residual stress is sensitive to friction condition of the tool-chip interfa ce. Simulation results offer an insight into residual stresses induced in s equential cuts. Based on simulation results, characteristics of residual st ress distribution can be controlled by optimizing the second cut. (C) 2000 Elsevier Science Ltd. All rights reserved.