A new way of identifying, predicting and regulating residual stress after chip-forming machining

Abstract Residual stresses are the result of distortion of the equilibrium forces on the surface of the material, which leads to its deformation and distribution of unevenness of the machined surfaces. The paper presents a new approach for the prediction of residual stress distribution after milling. This method for solving residual stress and predictions is highly dependent on material properties and therefore provides substantial improvement and modelling of the transformation states of the material that is necessary to reliably predict its behaviour under the conditions of the functional load. It has been found that roughness and roughness control determine the intensity of residual stress. Samples made of hardened steel X37CrMoV5-1 were used as the experimental material. A Proto iXRD diffractometer was used for residual stress measurement. The validity of the proposed method is confirmed by the good agreements between the theoretical, experimental results and results obtained from a literature survey.