Abstract The machining-induced residual stress has a pivotal impact on the corrosion resistance, fatigue, and functionality of manufactured components. Tool wear process induces the tool geometrical alterations, thereby affects the thermo-mechanical loads and residual stress distribution in the manufactured components. This work proposed a multi-physics model with the considerations of wear induced tool geometrical alterations to predict the residual stresses distribution for orthogonal turning Ti-6Al-4 V. These tool geometrical alterations included the flank wear, cutting edge radius, and rake angle. The proposed model framework involved five steps: (i) cutting force, (ii) temperature distribution, (iii) mechanical stress, (iv) thermal stress, and (v) calculation residual stresses by relaxation procedure. The experimental results verified that this model could effectively evaluate the residual stress distribution characteristics under tool wear conditions. Based on the prediction results, the response relationship analysis between the residual stresses and tool wear conditions was developed. This work could provide a novel method to control the residual stress distribution through monitoring of the tool wear morphology.

中文翻译：

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不同刀具磨损形态下正交切削Ti-6Al-4V多物理场残余应力预测

摘要 加工引起的残余应力对制造部件的耐腐蚀性、疲劳性和功能性具有关键影响。刀具磨损过程会引起刀具几何形状的变化，从而影响制造部件中的热机械载荷和残余应力分布。这项工作提出了一个考虑磨损引起的刀具几何变化的多物理模型，以预测正交车削 Ti-6Al-4 V 的残余应力分布。这些刀具几何变化包括后刀面磨损、切削刃半径和前角。提出的模型框架涉及五个步骤：(i) 切削力，(ii) 温度分布，(iii) 机械应力，(iv) 热应力，以及 (v) 通过松弛程序计算残余应力。实验结果验证了该模型能够有效评估刀具磨损条件下的残余应力分布特性。根据预测结果，建立了残余应力与刀具磨损条件之间的响应关系分析。这项工作可以提供一种通过监测刀具磨损形态来控制残余应力分布的新方法。