Prediction of Cutting Surface Residual Stress and Process Optimization for Aero-Engine Superalloy Bolts

The control of surface residual stress is paramount for ensuring the mechanical performance and longevity of machined GH2132 superalloy bolts. However, direct measurement of residual stress remains challenging. This study introduces a novel, efficient approach by establishing a quantitative correlation between Vickers hardness and residual stress based on the energy indentation method. The core hypothesis leverages the principle that residual stress modifies the indentation work; the difference in energy dissipation between stressed and stress-free states provides a direct measure of residual stress. A mathematical model relating hardness (HV) to residual stress (σ) was derived. To validate the model and unravel the underlying microstructural mechanisms, orthogonal cutting experiments were conducted. Comprehensive microstructural characterization using SEM, XRD, and metallography revealed a synchronous relationship between hardness and residual stress. Both properties increased concurrently with greater grain refinement and higher volume fraction/distribution density of carbides and γ’ phases, which impede dislocation motion and introduce micro-strain. The model predictions showed excellent agreement (R2 = 92.5%) with X-ray diffraction measurements, confirming its reliability. Furthermore, the influence of cutting parameters (speed Vc, feed f, depth of cut ap) on residual stress was analyzed. Cutting depth was identified as the most significant factor. An optimal parameter combination (Vc = 20 m × min−1, f = 1 mm × rev−1, ap = 1.2 mm) was identified to maximize beneficial compressive residual stress, corresponding to the most refined microstructure. This work presents a validated, hardness-based model for residual stress assessment in GH2132 and provides a microstructure-guided pathway for optimizing machining processes to enhance component life.