Modeling of machining-induced residual stresses

Machining-induced residual stresses not only have great influence on the fatigue life of machined components, but also can cause serious distortion in machining of components with large sizes. Thus, it is of great significance to predict and control residual stresses induced by machining. This paper reviews the exploration of residual stress prediction models and three main methods for predicting residual stresses during the last few decades, i.e., empirical, analytical and finite element methods (FEMs), which are introduced in detail. Empirical methods together with effects of different cutting parameters and influential factors on residual stress are classified according to the published experimental results. They are convenient but have limited application range since they are usually established under certain conditions. Analytical methods, which aim at theoretically investigating the instantaneous stresses and temperature induced by machining and revealing how residual stresses are accumulated during the machining process, are explained and discussed according to the evolution histories of all existing approaches. It is observed that different approaches together with some relevant machining mechanisms are merged into the analyzing procedures. Finite element methods, which are adopted to intuitively simulate the machining process, are reviewed at the end of this paper. It is found that FEMs are helpful to study the influential factors and to bridge industry-relevant parameters, but have low efficiency, especially for the three-dimensional models. Advantages and disadvantages corresponding to every model are discussed and summarized. From comprehensive review, it can be concluded that developing a more accurate residual stress measuring method, establishing a more general analytical model and improving the computational efficiency of finite element analysis are greatly desired.