Finite element modeling of the effects of tool corner radius on residual stresses distribution in cutting AISI4340

Residual stresses on a machined surface are one of the crucial factors in determining surface quality. Residual tensile stresses can be harmful for a machined workpiece, such as fatigue life, corrosion and wear resistance, whereas residual compressive stresses field is usually considered to have a positive influence on these aspects. In this paper, the Arbitrary- Lagrangian-Euler finite-element method was used to model the effects of tool corner radius on cutting residual stresses distribution when orthogonal dry cutting austenitic stainless steel AISI4340, which was set up in Abaqus/Explicit 6.8. Johnson- Cook material model was used to obtain the instantaneous strain and stress field in the machined wokpiece surface and subsurface, then the residual stresses were calculated using the plastic flow theory and relaxation of boundary restriction after the temperature to 20 degree. The analysis was done in two steps, the first step simulated the cutting process while the second one simulated the stress-relaxation process and the workpiece was left to cool down to room temperature. The results agree well with A.B.Sadat's job which was published in 1986 on Journal of Manufacturing Processes.