Analytical modeling of milling residual stress under different tool wear conditions.

The machining residual stress generated on the surface of the machined parts during machining has a crucial influence on the machining accuracy, fatigue strength, and corrosion resistance of the parts. Tool wear will aggravate the tool-work friction, and the thermal and mechanical load will change significantly, affecting the residual stress distribution. The distribution of 3D oblique cutting mechanical stress and thermal stress during tool wear is predicted by analyzing the 3D contact state of quick oblique cutting. The incremental thermal-elastic–plastic method is used for stress loading, and the 3D relaxation method is used for stress release to obtain residual stress. An analytical residual stress model considering tool wear is proposed to predict the residual stress distribution in milling, while aluminum alloy 7075-T6 is used as the workpiece in the case study. The results show that with the increase of tool wear, the residual stress of machined surface transfers from compressive stress to tensile stress, the value of sub-surface residual compressive stress increases the peak value of compressive stress moves more resounding, and the thickness of residual stress layer increases significantly. The average error between the predicted and experimental values is about 23.3%, which proves the model's validity and provides a new idea for controlling the distribution of machining residual stress. [ABSTRACT FROM AUTHOR]