Numerical evaluation of residual stresses induced during metal cutting

Abstract

Residual stress analysis plays a very important role in the structural safety and stability of the component. Residual stress has a great influence on the fatigue life of the structures. Residual stress reduces the load carrying capacity along with source of crack generation. The analysis of residual stress is complicated as it depends upon the tool geometry and cutting parameters. This work focuses on the effects of tool geometry and cutting parameters on residual stress in orthogonal machining of Aluminum 1100-0 using the finite element method (FEM) simulation. Explicit dynamics analysis is carried out in ANSYS Workbench. The results reveal the variation of residual stress as a function of tool geometry, depth of cut, nose and the machining speed. The results provide the inter relation between the residual stress and afore mentioned parameters