Prediction of residual stress with multi-physics model for orthogonal cutting Ti-6Al-4V under various tool wear morphologies

The machining-induced residual stress has a pivotal impact on the corrosion resistance, fatigue, and functionality of manufactured components. Tool wear process induces the tool geometrical alterations, thereby affects the thermo-mechanical loads and residual stress distribution in the manufactured components. This work proposed a multi-physics model with the considerations of wear induced tool geometrical alterations to predict the residual stresses distribution for orthogonal turning Ti-6Al-4 V. These tool geometrical alterations included the flank wear, cutting edge radius, and rake angle. The proposed model framework involved five steps: (i) cutting force, (ii) temperature distribution, (iii) mechanical stress, (iv) thermal stress, and (v) calculation residual stresses by relaxation procedure. The experimental results verified that this model could effectively evaluate the residual stress distribution characteristics under tool wear conditions. Based on the prediction results, the response relationship analysis between the residual stresses and tool wear conditions was developed. This work could provide a novel method to control the residual stress distribution through monitoring of the tool wear morphology.