M. Vosough, I. Svenningsson, AB Sandvik Coromant, Sandviken, Sweden; V. Kalhori, Luleå University of Technology, Luleå, Sweden; P. Liu, AB Sandvik Materials Technology, Sandviken, Sweden
Residual stresses from machining process can cause severe failure such as fatigue and stress corrosion. Ti-6Al-4V alloy is widely used in aerospace industry owing to its high strength to weight ratio. However, this alloy is experienced to be difficult to machine due to its rigidity and poor thermal conductivity. In this paper a coupled thermo-mechanical model of the plane strain orthogonal cutting process is used to study the effect of high-pressure jet-assisted machining. The finite element simulations using the updated Lagrangian formulation have been used to study the dynamic transient process. The surface and depth profile of residual stress was measured for high-pressure water-jet assisted machining by using x-ray diffraction as well. It showed the amount of residual compression stresses in both cutting and feed directions increases. The presence of compression residual stresses leads to a better surface integrity and consequently improves the properties of work metals such as fatigue.
Summary: Ti-6Al-4V rod was machined using different cooling system, high pressure and conventional. The residual stresses in surface and depth of cut was measured by x-ray and simulated by the finite element method. The present of compressional residual stresses was confirmed in the both methods.
