Finite Element Modeling to Verify Residual Stress in Orthogonal Machining

The aim of this thesis paper, to create a numerical model to examine the residual stresses induced by orthogonal machining in the finished work piece and the model is validated by comparing with experimental result. The finite element method is used to simulate and analyze the residual stresses induced by a orthogonal metal cutting process. A Dynamics explicit time integration technique with Arbitrary Lagrangian Eulerian (ALE) adaptive meshing Finite Element Method (FEM) is employed to simulate the model. The Johnson-Cook material model is used to describe the work material behaviour and fully coupled thermalstress analysis are combined to realistically simulate high speed machining with an orthogonal cutting. Finite Element modelling of Residual stresses and resultant surface properties induced by round edge cutting tools is performed as case studies for high speed orthogonal machining of 20NiCrMo5 steel. As a conclusion we can say that results from 2D simulations are very close to the experimental results at the surface level, but there is bit difference when we go down in the material. In 3D simulation, results agree with the experimental values in all levels So we can say that it is possible to model residual stresses, induced by orthogonal machining with accepted amount of accuracy.