3D numerical modelling of turning-induced residual stresses – A two-scale approach based on equivalent thermo-mechanical loadings

Nowadays, fatigue life of engineering components is a major topic. In the literature, extensive works have been reported in order to assess machining-induced surface integrity which known be first-order parameter for resistance. This paper lies framework turning-induced residual stress prediction by presenting an up-dated method based on two-scale approach. Previous aimed at building 3D hybrid consist modelling turning consequences through equivalent thermo-mechanical loadings combining finite element model with experimental tests. The new proposed global strategy keeps same concept but has advantage defining shapes more accurately thanks local 2D orthogonal cutting models. Moreover, calibration easier as only forces measured, makes it accessible end-users. Finally, provides results considering effective machined topography instead basic flat surface. After carefully detailing each step numerical method, validation case study concerning longitudinal operation 15-5PH martensitic stainless steel proposed. By comparing stresses coming from X-Ray diffraction, shows its superiority predict, within few hours, much accuratly state induced real operation.