3D Numerical modelling of machining induced residual stresses in aluminum A2024

Machining processes significantly influence surface integrity, particularly through the generation of residual stresses in near-surface layers. These stresses are critical for component performance, as they directly affect fatigue life and corrosion resistance. This study investigates finish boring/turning of the aluminium alloy A2024, a material widely used in aeronautics where high surface integrity is essential. The work is based on a 3D hybrid multi-pass numerical approach implemented in the MISULAB software. This method combines thermo-mechanical modelling with process-induced loadings to predict machining-induced residual stresses. It explicitly accounts for the cumulative effects of successive tool passes on the subsurface state. The numerical results are validated against experimental measurements obtained via X-ray diffraction, demonstrating strong agreement and confirming the reliability of the modelling strategy. A key focus is placed on the role of cutting tool micro-geometry, including rake angle and edge sharpness. The findings reveal that tool geometry has a major influence on both the magnitude and penetration depth of residual stresses. Depending on cutting conditions, tensile stresses can reach up to +300 MPa, approaching the material’s yield strength. These results provide valuable insights for optimizing machining parameters to better control surface integrity and enhance fatigue performance.