Achieving machining residual stresses through model-driven planning of process parameters

Steven Y. Liang, Carl R. Hanna, Ru-Min Chao

Research output: Chapter in Book/Report/Conference proceedingConference contribution

4 Citations (Scopus)

Abstract

The residual stress profile in a machined workpiece is often one of the important integrity attributes because of its direct effect on fatigue life. Machined residual stresses are difficult to predict due to the complicated interactions between chip formation, ploughing, transient stresses distributions, temperature gradients, and material responses during cutting. A fair amount of study has been documented to predict residual stress in a workpiece using analytical, experimental, and numerical modeling methods. However, machining process planning often needs to achieve specified residual stresses by the selection of process parameters and tool geometries. No method has been available that could calculate cutting process and tool geometry parameters based on final residual stresses as pre-specified inputs. This paper presents a physics-based modeling approach to quantitatively suggest the cutting condition and tool geometry parameters according to pre-specified surface residual stresses resulting from machining. To achieve this, inverse calculations procedures for the rolling/sliding contact theory, the McDowell hybrid residual stress algorithm, the specific cutting energy, and the Waldorf slip line model are developed to construct the quantitative model. Experimental data are used for model validation. The outcome of this study provides a methodology for the planning of process parameters and tool geometry to achieve prespecified residual stresses into machined parts.

Original languageEnglish
Title of host publicationTransactions of the North American Manufacturing Research Institution of SME - Paper Presented at NAMRC 36
Pages445-452
Number of pages8
Publication statusPublished - 2008 Sep 29
EventTransactions of the North American Manufacturing Research Institution of SME - Monterrey, Mexico
Duration: 2008 May 202008 May 23

Publication series

NameTransactions of the North American Manufacturing Research Institution of SME
Volume36
ISSN (Print)1047-3025

Other

OtherTransactions of the North American Manufacturing Research Institution of SME
CountryMexico
CityMonterrey
Period08-05-2008-05-23

Fingerprint

Residual stresses
Machining
Planning
Geometry
Process planning
Thermal gradients
Stress concentration
Physics
Fatigue of materials

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

Cite this

Liang, S. Y., Hanna, C. R., & Chao, R-M. (2008). Achieving machining residual stresses through model-driven planning of process parameters. In Transactions of the North American Manufacturing Research Institution of SME - Paper Presented at NAMRC 36 (pp. 445-452). (Transactions of the North American Manufacturing Research Institution of SME; Vol. 36).
Liang, Steven Y. ; Hanna, Carl R. ; Chao, Ru-Min. / Achieving machining residual stresses through model-driven planning of process parameters. Transactions of the North American Manufacturing Research Institution of SME - Paper Presented at NAMRC 36. 2008. pp. 445-452 (Transactions of the North American Manufacturing Research Institution of SME).
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Liang, SY, Hanna, CR & Chao, R-M 2008, Achieving machining residual stresses through model-driven planning of process parameters. in Transactions of the North American Manufacturing Research Institution of SME - Paper Presented at NAMRC 36. Transactions of the North American Manufacturing Research Institution of SME, vol. 36, pp. 445-452, Transactions of the North American Manufacturing Research Institution of SME, Monterrey, Mexico, 08-05-20.

Achieving machining residual stresses through model-driven planning of process parameters. / Liang, Steven Y.; Hanna, Carl R.; Chao, Ru-Min.

Transactions of the North American Manufacturing Research Institution of SME - Paper Presented at NAMRC 36. 2008. p. 445-452 (Transactions of the North American Manufacturing Research Institution of SME; Vol. 36).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Liang SY, Hanna CR, Chao R-M. Achieving machining residual stresses through model-driven planning of process parameters. In Transactions of the North American Manufacturing Research Institution of SME - Paper Presented at NAMRC 36. 2008. p. 445-452. (Transactions of the North American Manufacturing Research Institution of SME).