Machining-induced residual stress: Experimentation and modeling

Controlled orthogonal and controlled oblique machining of annealed AISI 434 0 have been undertaken in a design of experiments framework to investigate the machining induced residual stresses resulting from these processes. The experimentation demonstrates significant simplifications in the machining- induced residual stress problem when the stresses are expressed in a coordi nate system fixed in the tool and also indicates that the directions along the cutting edge and normal to the cutting edge of the tool are principal d irections of the machining-induced residual stresses. Based on the experime nts results, a plane strain thermoelastoplastic model of metal flow under t he flank of a cutting tool is developed to predict the full in-plane biaxia l residual stress profiles existing at and beneath the newly created surfac e. Calibrated results show favorable agreement with the experimental machin ing-induced residual stresses in annealed AISI 4340.