Finite element analysis of the effect of tool edge radius on residual stresses when orthogonal cutting Ti6Al4V

Abstract

A finite element analysis is presented based on the machining simulation software AdvantEdge FEM to investigate the effect of tool edge radius on residual stresses when orthogonal dry cutting Ti6Al4V alloy. Five types of cemented carbide tools with different tool-edge radius were used in the simulation. The results obtained from this study show that the residual stress at the machined surface is residual compressive stress and become more tensile than compressive beneath the machined surface for five radii. Tool-edge radius affects the magnitude and distribution of residual stress significantly, the magnitude of residual compressive stress, the thickness of compressive layer and the magnitude of residual tensile stress increase with the increase of tool-edge radius. A theoretical guidance for the control of residual stresses and optimization of tool-edge design can be provided in this study.