2D Modelling of Residual Stresses in Hard Turning of AISI 4140 Steel
Mehmet Erdi KORKMAZ Nafiz YAŞAR Mustafa GÜNAY
AbstractThe residual stresses induced by any machining process affects fatigue life, corrosion crack resistance and part distortion. Therefore, residual stresses should be predicted better and the cutting parameters should be arranged for minimum value. This paper presents a 2D finite element analysis (FEA) on residual stresses during hard turning of AISI 4140 steel with HSS tools. The cutting parameters are chosen as feed rate and cutting speed with three levels and constant depth of cut. In simulation after the cutting process is finished, both the chip and tool are removed and the workpiece can thermo-mechanically relax. The average of three extraction points on eight different depths of machined surface for residual stresses is calculated for better results. FEA results showed that both tangential and axial residual stresses act as tensile in the depths near the surface until about 75 µm while they act as compressive stress after the depth of 75 µm until about 300 µm. Also, increasing cutting speed has decreasing effect on tensile residual stresses while increasing effect on compressive residual stresses.