Idea of global sustainable development dictates greener machining processes. Cryogenic machining technologies enable cleaner, more energy efficient and less health hazardous process with possible lower production costs and higher productivity. In this paper, a 2D orthogonal cryogenic cutting process simulation model to predict the thermo-mechanical fields and the residual stress distribution remains in the machined surface of AZ31B magnesium alloy has been developed using ABAQUS FEM software. The proposed model can be applied to analyze influence of cutting condition parameters on the cutting forces and on the residual stress distribution in the machined surface and subsurface, which is a critical issue concerning energy efficiency and surface integrity of a cutting process.

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