Mathematical modelling and integration of micro-scale residual stresses into axisymmetric FE models of Ti6Al4V alloy in turning

The models are experimentally validated using face turning and the residual stress profile of a Ti6Al4V workpiece is generated and measured at two cutting depths (100 and 500 μm). The feed rate is kept constant at 100 μm/rev. Two residual stress measurement methods (X-ray diffraction and hole-drilling) are utilised in the current study. The X-ray diffraction method is used to measure the residual stress profiles on the surface of the machined workpiece. Compressive near the surface residual stresses are measured. The experimentally measured and the FE predicted residual stresses are in good agreement.