Numerical and experimental study of residual stress induced by machining process

Machining processes are widely used in different industries to cut different engineering parts. Usually, optimisation of these processes is made by experimental or numerical simulations. In particular, surface integrity modelling of the final piece is very important for the fatigue behaviour. In this paper modelling of the residual stresses in the fresh workpiece produced is studied. In particular finite element modelling using ABAQUS Explicit is employed in order to simulate chip formation and an implicit static calculation is made to have spring back in the workpiece after cooling. Orthogonal cutting process is chosen because it is simple and practice and different calculations method and numerical options are employed in order to replicate as well as possible physics during the process. In particular it is taken into account the cutting radius of the tool and the boundaries conditions of the workpiece. The setting of the numerical model is executed regarding the experimental conditions used. In the experimental section a complete study of the influence of the residual stresses by process variables (feed, cutting speed) is presented.