Abstract
The residual stresses in the machined surface layer are often critical to the strength. In the case of two phase alloys, the heterogeneous field of the residual stresses must affect it. Hence, a new finite element modeling is proposed to analyze and evaluate the residual stresses in the machined surface layer of two phase alloys. In this model, in order to simulate the chip separation during the cutting process, a part of elements in the workpiece is erased when the tool moves against the workpiece. The proposed finite element model is applied to the workpiece of carbon steels which are composed of ferrite and pearlite. The simulated and experimental results are compared and found to show good agreement. The large tensile residual stress on the machined surface appears on the pearlite area. The chip shape is complicated due to difference in the material properties between ferrite and pearlite.
