36. Modeling of Mechanical Residual Stresses in Micro-End Milling of Ti-6Al-4V Alloy

Wide range applications of micro-components make micromachining an important manufacturing method in industry. The distribution of machining-induced residual stresses has significant effects on the fatigue life, corrosion resistance, precision, and durability of parts. This study is focused on the modeling and validation of the residual stress induced in the workpiece after micro-end milling of Ti-6Al-4V. A coupled elasto-plastic model of mechanical stress inside the workpiece was developed to predict the residual stress. The contact between the cutter edge and the shear plane are considered a rolling contact which admits isotropic hardening only. In order to validate the developed residual stress model on the machined surface was evaluated by comparing the published literature result with similar cutting condition. It was found that the experimental and predicted values of both model and experimental results show hook-shaped distribution, with good agreement.