Effect of Cutting Parameters on Residual Stress for Ti1023 Using FEM and RSM

Machining induced residual stress has a major influence on the life time of machined parts, especially in their corrosion resistance and fatigue life. In this paper, finite element model (FEM) and response surface methodology (RSM) are applied to investigate the residual stress for machining titanium alloy Ti1023. The process of orthogonal cutting Ti1023 is successfully simulated by FEM using Power-Law constitutive model. The formation mechanism of residual stress is briefly described utilizing elastoplastic theory. Based on the analysis and simulations, the residual stresses profile in cutting and feed direction are successfully explained. Then, RSM is introduced to study the effects of the cutting speed and feed on surface residual stress. The results show that their interactions have no significant influence on surface residual stress. And the cutting speed and feed has strong nonlinear effect on surface residual stress.