Effects of Processing Parameters and Tool Geometric Parameters on Residual Stress of Machined 304 Stainless Steel

The machined surface residual stress plays a critical role in stress corrosion cracking resistance and fatigue performance of austenitic stainless steels. Controlling the residual stress by changing machining parameters is an effective way to improve the service performance of components. This paper explores the effects of processing parameters and tool geometric parameters on residual stress by establishing an analytical model for residual stress evaluation on machined surface. Considering the thermo-mechanical coupling effects of machining, a multi-physics framework of orthogonal cutting process is built up. From the coupling mechanical and thermal loads, the variations of stress, strain and temperature are modelled by an elastoplastic procedure. Based on the mechanism of residual stress and the loading-unloading model, the prediction of residual stress is achieved. Experimental tests are conducted for model validation. By simulating the cutting processes under different conditions and analyzing the main factors that affecting the stress/strain and temperature fields, the effects of cutting parameters and tool geometric parameters on residual stress are revealed.