Residual stress prediction based on MTS model during machining of Ti-6Al-4V

The material microstructure attributes are largely ignored in the machining community for the machining mechanics modeling. A physical-based mechanical threshold stress (MTS) model is proposed for the orthogonal turning application of Ti-6Al-4V material. The MTS model takes the material internal state variables, such as dislocation to dislocation interaction and dislocation/interstitial resistance, into the flow stress consideration. The MTS model is embedded into an analytical residual stress prediction model for machining induced residual stress prediction. The experimental data are provided for the model validation. The prediction generally captures the trend of the residual stress profile compared with experiments. The proposed model provides a microstructure insight of the workpiece material in the machining process modeling.