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TECHNICAL PAPERS

Machining-Induced Residual Stress: Experimentation and Modeling

[+] Author and Article Information
Kurt Jacobus, R. E. DeVor

S. G. Kapoor

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801

J. Manuf. Sci. Eng 122(1), 20-31 (Jun 01, 1999) (12 pages) doi:10.1115/1.538906 History: Received May 01, 1998; Revised June 01, 1999
Copyright © 2000 by ASME
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References

Henriksen,  E. K., 1951, “Residual Stresses in Machined Surfaces,” Trans. ASME, 73, pp. 69–76.
Okushima,  K., and Kakino,  Y., 1972, “A Study of Residual Stress Produced by Metal Cutting,” Mem. Fac. Eng., Kyoto Univ., Jpn., 34, pp. 234–248.
Tsuchida,  K., Kawada,  Y., and Kodama,  S., 1975, “A Study of the Residual Stress Distributions by Turning,” Bull. Jpn. Inst. Met., 18, pp. 123–130.
Liu,  C. R., and Barash,  M. M., 1982, “Variables Governing Patterns of Mechanical Residual Stress in a Machined Surface,” J. Eng. Ind. Trans. ASME, 104, pp. 257–264.
Matsumoto,  Y., Barash,  M. M., and Liu,  C. R., 1986, “Effect of Hardness on the Surface Integrity of AISI 4340 Steel,” J. Eng. Ind. Trans. ASME, 108, pp. 169–175.
Merwin,  J. E., and Johnson,  K. L., 1963, “An Analysis of Plastic Deformation in Rolling Contact,” Proc. Inst. Mech. Eng., 177, pp. 676–690.
Wu,  D. W., and Matsumoto,  Y., 1990, “Effect of Hardness on Residual Stresses in Orthogonal Machining of AISI 4340 Steel,” J. Eng. Ind. Trans. ASME, 112, pp. 245–252.
Thomsen,  E. G., Lapsley,  J. T., and Grassi,  R. C., 1953, “Deformation Work Absorbed by the Workpiece During Metal Cutting,” Trans. ASME, 75, pp. 591–603.
Jang, D. Y., and Seireg, A., 1990, “A Model for Predicting Residual Stresses in Metal Cutting,” Proceeding of the Japan International Tribology Conference, pp. 439–444.
Shih,  A. J., 1995, “Finite Element Simulation of Orthogonal Metal Cutting,” J. Eng. Ind. Trans. ASME, 117, pp. 84–93.
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Hsu, H.-C., 1992, “An Elasto-Viscoplastic Finite Element Model of Orthogonal Metal Cutting for Residual Stress Prediction,” Ph.D. thesis, North Carolina State University.
Morrow, D., 1982, “Stress-Strain Response of a Two-Bar Structure Subject to Cyclic Thermal and Steady Net Section Loads,” Master’s thesis, University of Illinois.
Johnson K. L., and Jefferis, J. A., 1963, “Plastic Flow and Residual Stresses in Rolling and Sliding Contact,” Proceeding of the Symposium on Fatigue in Rolling Contact, Institute of Mechanical Engineers, London, pp. 54–65.
Palmer, W. B., and Yeo, R. C. K., 1963, “Metal Flow Near the Tool Point During Orthogonal Cutting with a Blunt Tool,” Proceedings of the 4th International Machine Tool Design and Research Conference, Pergamon, Oxford, pp. 61–71.
Enahoro,  H. E., and Oxley,  P. L. B., 1966, “Flow Along Tool-Chip Interface in Orthogonal Metal Cutting,” J. Mech. Eng. Sci., 8, No. 1, pp. 36–41.
Taylor,  G. I., and Quinney,  H., 1934, “The Latent Energy Remaining in a Metal after Cold Work,” Proc. R. Soc. London, Ser. A, 145, pp. 362–387.
Sekhon,  G. S., and Chenot,  J. L., 1993, “Numerical Simulation of Continuous Chip Formation during Non-Steady Orthogonal Cutting,” Eng. Comput., 10, pp. 31–48.

Figures

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Schematic of the experimental setup (not to scale)
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Experimentally measured residual stress profiles: controlled orthogonal tests in tool and workpiece coordinate frames
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Experimentally measured residual stress profiles: controlled oblique tests (inclination angle 9°) in workpiece coordinate frames
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Experimentally measured residual stress profiles: controlled oblique tests in tool coordinate frames
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Experimentally measured residual stress profiles: controlled oblique tests at inclination angle i of 24 deg in workpiece and tool coordinate frames
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Schematic model for the development of machining-induced residual stress
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Possible residual stress fields resulting from the one-dimensional rationale
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Comparison of calibrated predictions and experimentally determined residual stress σ11r
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Comparison of calibrated predictions and experimentally determined residual stress σ33r
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Predicted residual stress profiles into the depth of the workpiece

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