Experimental and FEM Study of Residual Stresses During Ultra-Precision Turning of Aluminum 2024-T3

Aluminum 2024-T3 is commonly used in ultra-precision turning. In this study, the residual stresses of aluminum 2024-T3 were investigated by the finite element method (FEM) and a series of cutting experiments. The effects of depth of cut, cutting speed, rake angle and tool edge radius on the residual stresses were discussed by FEM. Moreover, an orthogonal simulation experiment was also conducted. The order of the strong-to-weak sequence of factors on residual stresses in cutting direction is the rake angle, tool edge radius, depth of cut and cutting speed. The cutting experiments were conducted and the surface residual stresses in the cutting direction were measured by X-ray diffraction. The experimental results showed that increasing cutting speed and decreasing tool edge radius can reduce the surface residual stresses.