Measurement of Surface Residual Stresses Generated by Turning Thin-Wall Ti6Al4V Tubes Using Different Cutting Parameters

Abstract In the present study, finite element analysis (FEA) was used to determine the optimal required length of the workpiece, taking into consideration factors such as accuracy, convenience, and materials saving. A new and highly accurate FEA-based correction method involving simple calculations was proposed. The method was used in conjunction with XRD to determine the surface residual stresses of Ti6Al4V tubes and analyze the effects of different turning parameters and annealing. It is found that the compressive residual stresses in cutting and feed directions will increase with increasing of cutting velocity, feed rate, and depth of cut within specific ranges, and that annealing will produce approximately 85% stress relaxation near the surface in both directions.