3D numerical modelling of residual stresses induced by reaming

The fatigue life of safety components is a major issue for many economic sectors, including aeronautics and energy. In the scientific literature, the link between surface integrity, particularly residual stresses, and fatigue life has long been established. The objective of this paper is to predict the residual stresses induced by a reaming operation using a solid reamer. Previous works proposed a method to predict the residual stresses induced by a turning operation. This method, implemented in a finite element code, is based on the application of equivalent 3D thermomechanical loadings onto the final surface of a part. The method is called 'hybrid' because it uses experimental measurements of the cutting forces to calibrate the intensity of the thermomechanical loadings. This paper aims at adapting this 3D hybrid modelling method to the case of a reaming operation in a martensitic stainless steel. The model only considers the effects of major cutting edges and not the effects of the margins. A comparison between the numerical results and the experimental residual stresses measured from X-ray diffraction shows good accuracy of the model. It is revealed that the reaming operation has a significant effect on the residual stress state on the surface and that its action is dominated by plastic deformation, leading to compressive stresses.