Hybrid modeling prediction of residual stresses in turned Ti6Al4V considering frictional contact

Residual stress plays a pivotal role in assessing the surface quality of machined components, influencing characteristics such as fatigue performance, corrosion resistance, and mechanical strength. Ti6Al4V, a critical material in the nuclear sector, the generation of residual stresses during machining has attracted significant attention. A model for variable friction coefficient model is proposed to accurately characterize the complex plastic deformation behavior of the material. This model takes into account variables such as the relative sliding velocity, contact pressure, and temperature. A subroutine has been developed using the VFRIC interface to enhance precise cutting simulation and modeling. Using the friction model, a new hybrid prediction model for surface residual stresses is developed by integrating finite element analysis and analytical methods. The reliability of both the hybrid and friction models is confirmed through the evaluation of cutting forces, chip morphology, and residual stress. The findings suggest that the novel friction model produces simulation results with higher accuracy compared to traditional Coulomb friction models. The variations in cutting force amount to 5.8% and 13.7%, the error in chip serration is 12.4%, and the deviation in predicting the maximum residual compressive stress is 10.3%. This study contributes to the advancement of friction models and methodologies used in predicting residual stress.