Surface Integrity in Machining of AISI 1045 Steel Effect of Machining Parameters on Machining Induced Residual Stresses

Abstract

Machining is working with metal using various machine tools like the lathe, drill press, milling newlinemachine etc. to take precise cuts to transform metals in to products or components being newlineassembled in products. Sometimes it involves taking incredible small cuts, sometimes it is newlineremoval of large amount of material. Machining is one of the most common type of newlinemanufacturing process used with expenditures estimated at 5% of GDP of developing countries. newlineMachining is the general term used for a group of material removal process. Machining newlineproduces components of desired, size, shape surface finish, by removing successive layers of newlinematerial in the form of chips. It is a plastic deformation process which affects the material newlinephysically and metallurgically. newlineWhile the material undergoes plastic deformation, residual stresses are developed. Residual newlinestresses are integral part of structures and components. Any component produced by plastically newlinedeforming by various manufacturing processes will have the residual stresses. The nature and newlinemagnitude have favourable as well as detrimental consequence to the component s functional newlineperformances. newlineMany research studies have been conducted in the past for the experimental and numerical newlineinvestigation of cutting forces, temperatures, residual stresses and tool wear etc. during newlinemachining of AISI 1045 steel. A close agreement was found between experimental and newlinesimulated results, however, the available FE models for materials have generally been limited newlineto orthogonal machining. An effective predictive model to predict the machining induced newlineresidual stress during oblique cutting of metals is not present. newlineIn the present research work, extensive experimentation and numerical investigations have been newlineperformed to predict the machining induced residual stresses in the machining of AISI1045 newlinesteel and a code has been developed to optimize the machining parameters using particle swarm newlineoptimization technique. Experiments were done using two approaches, single factor at a time newlineand des