Numerical Study of Residual Stress Induced by Multi-steps Orthogonal Cutting

Residual stresses induced by material removal have a major influence on the lifetime of machined pieces especially in its corrosion resistance and fatigue life. For that reason, numerical prediction of residual stress profile was the subject of many works. But most of these models are developed only for a single step. They does not consider the effect of hardening and thermal softening on the residual stresses induced by the material removal which is, in the reality, a multi-steps operation such as milling and grinding. The cutting tool is in contact with a part of material that was the finished piece in the previous step. In this paper a multi-steps model for orthogonal cutting has been developed in order to study the influence of the cumulated strain and temperature induced by the different steps on the residual stresses. The effect of tool edge radius and heat generated by flank friction on the predicted stress profile is modeled. Commercial finite element software ABAQUS with its Explicit and Implicit modules was used. Computed Numerical predicted stress fields are compared against measured residual stresses obtained by X-Ray diffraction. Moreover, in order to take into account all the physics in the tool-work material interface, spring back simulation was performed using ABAQUS Implicit.