Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloyFinite Elemente basiertes Modell zur Abschatzung von induzierten Eigenspannungen und Schnittkraften in einer AISI 1020 (S 275 JR) Stahllegierung

The application of finite element models is a promising method for ensuring part quality during machining to accurately predict induced residual stresses and cutting forces. The present study applied Analysis System software to formulate a 3D model to predict induced residual stress and forces for AISI 1020 alloy. Taguchi method was applied in the design of the experiment with three levels and three factors selected: Cutting speed, feed rate and depth of cut. For validation, stresses are measured using an x-ray diffractometer from the surface to a depth of 0.6 mm in steps of 0.2 mm. The cutting forces are determined using a force dynamometer. Simulation results showed that cutting speed, feed rate and depth of cut contributed 94.76 %, 0.048 %, and 0.11 % respectively. The predictive model equations were statistically significant with a p-value of <0.005. The average induced residual stress on the superficial layer from the experiment and simulation were -367.7 MPa and -365.6 MPa respectively. The average residual stresses obtained at depths of 0.2 mm, 0.4 mm, and 0.6 mm were -260 MPa, -233 MPa, and -211 MPa, respectively. The proposed model offers a potential solution to reducing the costs of experimental methods.