FE analysis on the influence of sequential cuts on component conditions for different machining strategies

Performance and durability of highly stressed components are greatly affected by the component's state including residual stresses. For processes with multi-edged tools, sequential cuts influence the surface layer. A method to forecast the component state is developed by using FE simulations of multiple chip formation done by broaching of SAE 5120 low alloy steel. Remeshing describes material separation, allowing a high detailed resolution of the machined surface layer including the workhardened layer and the residual stress state. Implemented simulation method extracts information from the machined work piece and defines initial conditions for a new unmachined work piece model. The work analyses the influence of tool temperatures on residual stress states after machining. Effects on the stresses appear below the surface. The results are compared to residual stress measurements.