A modified time-efficient FE approach for predicting machining-induced residual stresses

Finite element analysis (FEA) has been widely used in predicting machining-induced residual stresses (RS); however, its high computational cost has been always an issue. The current work presents a modified time-efficient finite element (FE) approach for predicting machining-induced RS using commercial FE software. This approach cuts down the computational time for RS prediction from the order of days to just few minutes, which represents a significant contribution to the field of metal cutting and FEA applications. The commercial FE software ABAQUSTM was used in the current study; however, the presented approach could be applied to any other commercial FE software. Four different workpiece materials were used to validate the current work by comparing their predicted RS profiles to their experimental profiles, which were obtained under similar cutting conditions. In order to calculate the computational advantage of using the modified approach, the same RS profiles were predicted using the tradition FE approach, which is the only currently available FE approach in the literature. The RS profiles predicted by both approaches were almost identical, and they were both in reasonable agreement with the experimental ones.