Numerical and experimental investigations on residual stress evolution of multiple sequential cuts in turning

Residual stress is of great importance on the fatigue life of components; nevertheless, most of the simulations of turning operation focus on the first cut and ignore the evolution of residual stress in sequential cutting. The present study aims to explore the surface residual stress profile along the feed direction during longitudinal turning, to understand the impact of sequential cuts on turning-induced residual stress. A Coupled Eulerian–Lagrangian (CEL)-based three-dimensional (3D) numerical model is employed to stably predict the evolution of residual stress of multiple sequential cuts in turning integrated with complete material removal process of each cut. The effectiveness and accuracy of the proposed model are verified though the good agreement between simulated and measured results. The results show that the surface residual stress gradually decreases with increasing cutting sequence under the condition of different tool nose radius and feed rates. It is also found that the main reason of this phenomenon is the residual stress state generated by the former tool path. For a single case, the drop of tensile residual stress from the first cut to the third cut can be more significant when a larger feed rate is employed.