Effect of cutting parameters on surface residual stresses in dry turning of AISI 1035 alloy

Residual stresses (RSes) induced by turning processes have a great effect on the material properties of the machined components and their abilities to withstand severe loading conditions (creep, fatigue, and stress corrosion cracking). The final state of RSes in a workpiece depends on its material and on the employed cutting parameters/conditions such as cutting speed, depth of cut, feed speed, cutting tool geometry, wear of the tool, cutting tool geometry, cutting tool coating, and cooling. This study introduces a comprehensive investigation of the effects of different cutting parameters, such as cutting speed (30, 60, and 90m/min), feed (0.05, 0.1, and 0.3mm/rev), and depth of cut (0.1, 0.5, and 1mm) as well as cutting tool geometry such as cutting tool nose radius (0.397, 0.794, and 1.191mm), and cutting tool coating (coated and uncoated) on the cutting force, maximum cutting temperature, surface microstructure, and surface residual stresses during cutting AISI 1035 alloy steel. The RSes were measured using X-ray diffraction technique. The experiments were designed using Taguchi method based on L-18 orthogonal array, and the significance level of different cutting parameters as well as cutting tool properties have been determined via applying analysis of variance. Numerical simulations have been carried out using commercial machining software AdvantEdge.