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research-article

Analytical model of residual stress in dynamic cutting process

[+] Author and Article Information
Xin-Da Huang

No. 1037 Luoyu Road Wuhan, 430074 China
huangxinda@hust.edu.cn

Xiao-Ming Zhang

No. 1037, Luoyu Road Wuhan, 430074 China
zhangxm.duyi@gmail.com

Juergen Leopold

Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz 09661, Germany
jleopold@tbz-pariv.de

Han Ding

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
famt@hust.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4037424 History: Received January 24, 2017; Revised June 29, 2017

Abstract

Residual stress, one 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 of elastic-plastic deformation 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 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 lathe. The periodic residual stress distribution is predicted using the proposed approach, which is then validated against the X-ray diffraction measurements.

Copyright (c) 2017 by ASME
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