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Research Papers

Analytical Model for Prediction of Residual Stress in Dynamic Orthogonal Cutting Process

[+] Author and Article Information
Xin-Da Huang, Han Ding

State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China

Xiao-Ming Zhang

State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zhangxm.duyi@gmail.com

Jürgen Leopold

TBZ-PARIV GmbH,
Chemnitz 09126, Germany

1Corresponding author.

2Previously at Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz 09661, Germany.

Manuscript received January 24, 2017; final manuscript received June 29, 2017; published online November 3, 2017. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 140(1), 011002 (Nov 03, 2017) (17 pages) Paper No: MANU-17-1040; doi: 10.1115/1.4037424 History: Received January 24, 2017; Revised June 29, 2017

Residual stress, characteristic of surface integrity, is a great issue in cutting process for its significant effects on fatigue life and dimension stability of the machined parts. From a practical viewpoint, residual stress is generated in a dynamic tool-part engagement process, instead of a process with nominal cutting loads. This is the challenge that we have to handle, so as to achieve better predictive methods than the previously recorded approaches in literatures which ignore the dynamic effects on residual stress. This paper presents an analytical method for the prediction of residual stress in dynamic orthogonal cutting. A mechanistic model of the dynamic orthogonal cutting is provided, considering the indentation effect of the cutting edge during the wave-on-wave cutting process. Following the calculation of plastic strains by incremental analysis in mechanical loading, analytical solution of the residual stress due to distributed plastic strains in half-plane is obtained based on inclusion theory. Without relaxation procedures, the two-dimensional (2D) distribution of residual stress in dynamic cutting process is predicted for the first time. A delicately designed dynamic orthogonal cutting experiment is realized through numerical control (NC) lathe. The periodic residual stress distribution is predicted using the proposed approach, which is then validated against the X-ray diffraction measurements.

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Figures

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Fig. 1

2D distributed rectangular inclusions in semi-infinite plane

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Fig. 2

Superposition of solutions for rectangular inclusion in semi-infinite plane

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Fig. 3

Residual stress due to discrete distributed rectangular inclusions

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Fig. 4

Wave-on-wave cutting in dynamic cutting process

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Fig. 5

Contact boundary condition in dynamic cutting process with SDOF system

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Fig. 6

Dynamic plowing effect due to tool vibration

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Fig. 7

Wave-on-wave cutting with phase differences

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Fig. 8

The variation of stresses at z = 0.005 mm due to dynamic cutting in condition 3

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Fig. 9

The plastic strains in the workpiece under condition 3. Figures from (a) to (d) correspond to the simulation results of plastic strain components εxxp,εyyp,εzzp,γxzp, respectively.

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Fig. 10

Simulation result of residual stress in the workpiece under condition 1

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Fig. 11

Simulation result of residual stress in the workpiece under condition 2

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Fig. 12

Simulation result of residual stress in the workpiece under condition 3

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Fig. 13

Experiment setup for low frequency dynamic orthogonal cutting

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Fig. 14

Geometry of the cutting tool

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Fig. 15

Actual feed motion with harmonic oscillation: (a) time-domain signal and (b) frequency spectrum

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Fig. 16

Varying chip thickness in dynamic cutting

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Fig. 17

Measurement of residual stress distribution by X-ray diffraction analysis

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Fig. 18

Dynamic cutting forces and displacement of the tool with condition 1

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Fig. 19

Dynamic cutting forces and displacement of the tool with condition 2

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Fig. 20

Dynamic cutting forces and displacement of the tool with condition 3

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Fig. 21

Measured residual stresses distribution along the arc of machined surface in condition 3

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Fig. 22

Measured residual stresses along the arc of machined surface in condition 2

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Fig. 23

Measured residual stresses along the arc of machined surface in condition 1

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Fig. 24

Comparison between simulated and measured cutting forces in condition 3

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Fig. 25

Comparison between simulated and measured circumferential residual stresses in condition 3

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Fig. 26

Simulated plastic strains at z = 0.005 mm along the surface of disk in condition 3

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