3D Finite Element Analysis of Prestressed Cutting
In order to reveal the adjustment principle of prestressed cutting on the residual stress of hardened bearing steel GCr15, a three-dimensional thermal elastic-viscoplastic finite element model was developed using an Arbitrary Lagrangian Eulerian (ALE) formulation. Several key simulation techniques including the material constitutive model, constitutive damage law and contact with friction were discussed, simulation of chip formation during prestressed cutting was successfully conducted. At the prestresses of 0 MPa, 341 MPa and 568 MPa, distributions of residual stress on machined surface were simulated and experimentally verified. The results indicated that residual compressive stress on machined surface were achieved and actively adjusted by utilizing the prestressed cutting method; meanwhile, within the elastic limit of bearing steel material, the higher applied prestress leads to the more prominent compressive residual stress in the surface layer and subsequently the higher fatigue resistance of the part.
Liangchi Zhang, Chunliang Zhang, Jeng-Haur Horng and Zichen Chen
R. T. Peng et al., "3D Finite Element Analysis of Prestressed Cutting", Advanced Materials Research, Vols. 591-593, pp. 766-770, 2012