Surface Integrity In Machining of AISI 1045 Steel:

Effect Of Machining Parameters on Machining

Induced Residual Stresses
Project done by

Prakash Marimuthu K
(BL15PHCS237)

Under the guidance of

Dr. Thirtha Prasada H P Dr. Chethan Kumar C S

Supervisor Co-Supervisor

VISVESVARAYA TECHNOLOGICAL UNIVERSITY,

BELAGAVI, KARNATAKA
Contents
• Introduction
• Literature Survey
• Objectives
• Methodology
• Possible Outcome
• References
Introduction
• Machining is one of the plastic deformation processes that induce residual stresses
in the components.
• Residual stresses can be compressive or tensile, which in turn affect functional
performance like creep resistance, fatigue, corrosion resistance and so on.[1]
• The functional performance of components from material removal processes is
heavily influenced by the quality and reliability of the surfaces produced both in
terms of topography [2,3] as well as metallurgical state
• The present work deals with the prediction of the amount and nature of the
residual stresses that are induced during milling of components and study the
effect of machining parameters on the induced residual stresses.
Literature Survey
• Machining induced residual stresses has interested many researchers in the past.
The residual stresses can be optimized according to our requirement by optimizing
the cutting parameters and rake angle[4].
• Valiorgur et al., (2007) presented an approach to predict the residual stresses
induced in turning of 316L. The mechanism which generates the residual stresses
was captured and the same was used to predict the residual stresses [5].
• Li et al., (2009) made an FEM study on the machining induced residual stresses in
hardened SKD11(high carbon, high chromium) hardened steel. A 2D thermo-
mechanical model was developed. The researchers have used Johnson-Cook
material model for the simulations [6].
• Mohammadpour et al., (2010) did numerical investigation on orthogonal
machining. The effect of cutting parameters on the induced residual stresses were
predicted using a FE model [7].
Contd…
• Jawahir et al., (2011) presented the advancement that has taken place over the
years in surface integrity related matters pertaining to metal removal process. He
concluded that correlation between the cutting parameters and the functional
performances has to be established. [8]
• Ulutan and Ozel (2011) did an extensive review on the machining induced surface
integrity in engineered materials. They observed that there is lot of arguments
between the researchers particularly the nature, magnitude and effected on
machining induced residual stresses and further research is need along this lines[9].
• Kohler et al., (2012) studied the machining induced residual stresses in milled
titanium parts, he conclude that very little knowledge is available about the
influence of the machining processes which induce the residual stresses in
components. He also enumerated this of prime importance in the components that
are used in aerospace structures [10].
Objectives
• To review surface integrity in machining AISI 1045 steel.
• To develop a predictive model for residual stresses induced by machining
• To optimize the machining parameters that critically affect residual stresses
• To develop a FEA model to predict residual stresses and compare with
experimental results.
Methodology
• Identify the material removal process to be considered for the study.
• Identify the machining parameters that greatly influence the surface integrity of
the components.
• Identify the output parameters and Design a set of experiments
• Conduct of the experiments
• Developing predictive model and optimize the machining parameters that affect
the surface integrity.
• Develop a FEM model and simulate the experiments that were conducted and
compare the results.
Possible Outcome
• Mathematical model that could predict surface integrity quantitatively for a range
of machining parameters for AISI 1045 steel used in industry.
• To optimize the cutting parameters that affect the residual stresses induced during
the machining process.
• FEM model that can predict the induced residual stresses
• Provide a link between the induced residual stress and functional performance of
the components.
References
• [1] P. I. Varela, C. S. Rakurty, and A. K. Balaji, "Surface Integrity in Hard Machining of
300M Steel: Effect of Cutting-edge Geometry on Machining Induced Residual Stresses,"
Procedia CIRP, vol. 13, pp. 288-293, 2014.
• [2] Devries MF, Field M, Kahles JF (1976) Relationship of Surface Roughness and Surface
Integrity to Functional Properties. Annals of the CIRP 25(2):569–573
• [3] Novovic D (2004) The effects of machined workpiece surface topography and integrity
on fatigue life. PhD Dissertation, University of Birmingham.
• [4] P. Dahlman, F. Gunnberg, and M. Jacobson, "The influence of rake angle, cutting feed
and cutting depth on residual stresses in hard turning," Journal of Materials Processing
Technology, vol. 147, pp. 181-184, 2004.
• [5] F. Valiorgue, J. Rech, H. Hamdi, P. Gilles, and J. M. Bergheau, "A new approach for the
modelling of residual stresses induced by turning of 316L," Journal of Materials Processing
Technology, vol. 191, pp. 270-273, 2007.
Contd…
• [6] J. L. Li, L. L. Jing, and M. Chen, "An FEM study on residual stresses induced by high-speed
end-milling of hardened steel SKD11," Journal of Materials Processing Technology, vol. 209, pp.
4515-4520, 2009.
• [7] M. Mohammadpour, M. R. Razfar, and R. Jalili Saffar, "Numerical investigating the effect of
machining parameters on residual stresses in orthogonal cutting," Simulation Modelling Practice
and Theory, vol. 18, pp. 378-389, 2010.
• [8] I. S. Jawahir, E. Brinksmeier, R. M'Saoubi, D. K. Aspinwall, J. C. Outeiro, D. Meyer, et al.,
"Surface integrity in material removal processes: Recent advances," CIRP Annals -
Manufacturing Technology, vol. 60, pp. 603-626, 2011.
• [9] D. Ulutan and T. Ozel, "Machining induced surface integrity in titanium and nickel alloys: A
review," International Journal of Machine Tools and Manufacture, vol. 51, pp. 250-280, 2011.
• [10] J. Köhler, T. Grove, O. Maiß, and B. Denkena, "Residual Stresses in Milled Titanium
Parts," Procedia CIRP, vol. 2, pp. 79-82, 2012.
Thank You