Abstract:
The application of finite element models is a promising method for ensuring
part quality during machining to accurately predict induced residual stresses
and cutting forces. The present study applied Analysis System software to formulate a 3D model to predict induced residual stress and forces for AISI 1020
alloy. Taguchi method was applied in the design of the experiment with three
levels and three factors selected: Cutting speed, feed rate and depth of cut.
For validation, stresses are measured using an x-ray diffractometer from the
surface to a depth of 0.6 mm in steps of 0.2 mm. The cutting forces are determined using a force dynamometer. Simulation results showed that cutting
speed, feed rate and depth of cut contributed 94.76%, 0.048%, and 0.11% respectively. The predictive model equations were statistically significant with a
p-value of <0.005. The average induced residual stress on the superficial layer
from the experiment and simulation were 367.7 MPa and 365.6 MPa respectively. The average residual stresses obtained at depths of 0.2 mm,
0.4 mm, and 0.6 mm were 260 MPa, 233 MPa, and 211 MPa, respectively. The proposed model offers a potential solution to reducing the
costs of experimental me
