Three-Dimensional Numerical Modelling of Residual Stresses Induced in Surface Milling

Abstract The relationship between surface integrity, particularly residual stresses, and fatigue life is well-established. A model known as the "3D hybrid multi-pass model" has been previously developed to predict the 3D residual stress fields generated by longitudinal turning over multiple revolutions until a steady state is reached. This model simulates the generation of residual stresses by accounting for equivalent 3D thermo-mechanical loads, which are calibrated using cutting force measurements, as they move over the machined surface. The aim of this paper is to adapt this methodology for surface milling, where multiple cutting edges generate the surface at a much higher frequency. A case study on the surface milling of 15-5PH martensitic stainless steel is presented