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Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations

The surface residual stress after machining, especially for finishing, has a vital influence on the shape stability and fatigue life of components. The current study focuses on proposing an original empirical equation to predict turned surface residual stress for Inconel 718 material, taking tool pa...

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Autores principales: Peng, Huachen, Tang, Wencheng, Xing, Yan, Zhou, Xin
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8304668/
https://www.ncbi.nlm.nih.gov/pubmed/34300855
http://dx.doi.org/10.3390/ma14143937
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author Peng, Huachen
Tang, Wencheng
Xing, Yan
Zhou, Xin
author_facet Peng, Huachen
Tang, Wencheng
Xing, Yan
Zhou, Xin
author_sort Peng, Huachen
collection PubMed
description The surface residual stress after machining, especially for finishing, has a vital influence on the shape stability and fatigue life of components. The current study focuses on proposing an original empirical equation to predict turned surface residual stress for Inconel 718 material, taking tool parameters into consideration. The tool cutting-edge angle, rake angle, and inclination angle are introduced for the first time in the equation based on the Inconel 718 material turning experiments and finite element simulations. In this study, the reliability of simulation parameters’ setting is firstly calibrated by comparing the residual stresses and chips of the experiments and simulations. The changing trends of turned forces, temperatures of lathe tool nose, and surface residual stress with turning parameters are analyzed. Then, the predictive equation of surface residual stress is proposed considering relationships between the back-rake angle, the side-rake angle, and the tool cutting-edge angle, rake angle, and inclination angle. Moreover, the genetic algorithm optimizes the objective function to obtain the undetermined coefficients in the prediction equation. Finally, the predicted accuracy of the surface residual stress is proven by comparing the experimental, simulation, and prediction values. The results indicate that the predictive equation of surface residual stress has a good accuracy in predicting turned surface residual stress for Inconel 718 materials. The correlation coefficient, R, and absolute average error between the predicted and the simulated value are 0.9624 and 13.40%, respectively. In the range of cutting parameters studied and experimental errors, this study provides an accurate predictive equation of turned surface residual stress for Inconel 718 materials.
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spelling pubmed-83046682021-07-25 Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations Peng, Huachen Tang, Wencheng Xing, Yan Zhou, Xin Materials (Basel) Article The surface residual stress after machining, especially for finishing, has a vital influence on the shape stability and fatigue life of components. The current study focuses on proposing an original empirical equation to predict turned surface residual stress for Inconel 718 material, taking tool parameters into consideration. The tool cutting-edge angle, rake angle, and inclination angle are introduced for the first time in the equation based on the Inconel 718 material turning experiments and finite element simulations. In this study, the reliability of simulation parameters’ setting is firstly calibrated by comparing the residual stresses and chips of the experiments and simulations. The changing trends of turned forces, temperatures of lathe tool nose, and surface residual stress with turning parameters are analyzed. Then, the predictive equation of surface residual stress is proposed considering relationships between the back-rake angle, the side-rake angle, and the tool cutting-edge angle, rake angle, and inclination angle. Moreover, the genetic algorithm optimizes the objective function to obtain the undetermined coefficients in the prediction equation. Finally, the predicted accuracy of the surface residual stress is proven by comparing the experimental, simulation, and prediction values. The results indicate that the predictive equation of surface residual stress has a good accuracy in predicting turned surface residual stress for Inconel 718 materials. The correlation coefficient, R, and absolute average error between the predicted and the simulated value are 0.9624 and 13.40%, respectively. In the range of cutting parameters studied and experimental errors, this study provides an accurate predictive equation of turned surface residual stress for Inconel 718 materials. MDPI 2021-07-14 /pmc/articles/PMC8304668/ /pubmed/34300855 http://dx.doi.org/10.3390/ma14143937 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Peng, Huachen
Tang, Wencheng
Xing, Yan
Zhou, Xin
Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations
title Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations
title_full Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations
title_fullStr Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations
title_full_unstemmed Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations
title_short Semi-Empirical Prediction of Turned Surface Residual Stress for Inconel 718 Grounded in Experiments and Finite Element Simulations
title_sort semi-empirical prediction of turned surface residual stress for inconel 718 grounded in experiments and finite element simulations
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8304668/
https://www.ncbi.nlm.nih.gov/pubmed/34300855
http://dx.doi.org/10.3390/ma14143937
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