How can machining-induced residual stresses be effectively predicted and controlled? This research uses controlled orthogonal and oblique machining of annealed AISI 4340 within a design of experiments framework to investigate resulting residual stresses. The study demonstrates that expressing stresses in a tool-fixed coordinate system significantly simplifies the problem. The experimental results show that directions along and normal to the cutting edge are principal directions for machining-induced residual stresses. Based on these findings, the authors develop a plane strain thermoelastoplastic model to predict in-plane biaxial residual stress profiles at and beneath newly created surfaces. Calibrated results show good agreement with experimental machining-induced residual stresses in annealed AISI 4340. This refined understanding and predictive modeling capability enable better control of residual stress in machining processes, enhancing the quality and performance of manufactured components.
Aligned with the Journal of Manufacturing Science and Engineering's focus, this study addresses a critical aspect of manufacturing by investigating machining-induced residual stress. The combination of experimentation and modeling to predict residual stress profiles contributes to the journal's objective of advancing manufacturing process understanding and optimization.