Finite Element Modeling of the Residual Stresses in Orthogonal Machining Process

In this work, a thermo-mechanical numerical analysis of orthogonal machining process is performed to estimate the residual stresses induced in workpiece under plane-strain conditions. to determine the residual stresses, a finite element (fe) model with arbitrary lagrangian eulerin (ale) formulation is established by employing adaptive meshing and explicit dynamics solution techniques. when fe simulations are completed for the orthogonal cutting process of 20nicrmo5 steel, the cutting tool is withdrawn and the stresses are relieved. the results reveal that the machined surface is tensile stresses. the estimated residual stresses are also compared with experimentally measured data available in the literature. the residual stresses of the machined surface obtained from the fe simulations have a quite reasonable accuracy. the values of the tangential residual stresses determined from the fe analyses can be utilized to optimize cutting parameters and improve the life of mechanical components.