Analytical Model for Prediction of Residual Stress in Dynamic Orthogonal Cutting Process

Residual stress, characteristic of surface integrity, is a great issue in cutting process for its significant effects on fatigue life and dimension stability of the machined parts. From a practical viewpoint, residual stress is generated in a dynamic tool-part engagement process, instead of a process with nominal cutting loads. This is the challenge that we have to handle, so as to achieve better predictive methods than the previously recorded approaches in literatures which ignore the dynamic effects on residual stress. This paper presents an analytical method for the prediction of residual stress in dynamic orthogonal cutting. A mechanistic model of the dynamic orthogonal cutting is provided, considering the indentation effect of the cutting edge during the wave-on-wave cutting process. Following the calculation of plastic strains by incremental analysis in mechanical loading, analytical solution of the residual stress due to distributed plastic strains in half-plane is obtained based on inclusion theory. Without relaxation procedures, the two-dimensional (2D) distribution of residual stress in dynamic cutting process is predicted for the first time. A delicately designed dynamic orthogonal cutting experiment is realized through numerical control (NC) lathe. The periodic residual stress distribution is predicted using the proposed approach, which is then validated against the X-ray diffraction measurements.