Prediction of machining induced residual stresses in turning of titanium and nickel based alloys with experiments and finite element simulations
نویسندگان
چکیده
Titanium and nickel alloys represent a significant metal portion of the aircraft structural and en components and the residual stresses induced by machining are very critical due to safety sustainability concerns. This paper presents experimental investigations and finite element simulat on turning of Ti–6Al–4V titanium alloy and IN100 nickel based alloy with uncoated and TiAlN co tools. Face turning of Ti–6Al–4V and IN100 using uncoated tools with various edge radii and TiAlN co carbide tools is conducted; and residual stresses are measured in radial and circumferential direct using X-ray diffraction technique. 3-D finite element (FE) modeling is utilized to predict forces machining induced stress fields. The feasibility and limitations of predicting machining induced resi stresses by using viscoplastic finite element simulations and temperature-dependent flow softe constitutive material modeling are investigated. A friction determination method is utilized to iden friction coefficients in presence of tool edge radius. The predicted stress fields are compared aga measured residual stresses. Effect of tool edge radius and coating on the predicted stress profiles is investigated. The results are found useful in predicting machining induced surface integrity that is cri to determine the fatigue life of nickel and titanium alloy components. 2012 C
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