Machining a metal part will create residual stresses on its surface due to the deformation that the process introduces to it, is there any model to estimate how thick will this stress layer may be?

  • $\begingroup$ If you cut the surface, you actually cut through the grains, this kind of plastic deformation actually makes the metal stronger, (no residual stresses). if you forge it, then yes it creates residual stresses in the metals, so what kind of machining we are talking about ? and what type of materials ? cristalline ? amorf ? $\endgroup$
    – user14407
    Aug 24, 2018 at 18:55
  • $\begingroup$ @SamFarjamirad Cutting through the grains will produce stress in the material, there's no doubt about it. And, yes, the material hardens as you point out, that is one indication that you got stresses. Cold forging will also generate residual stresses, but they will be distributed throughout the solid. I'm looking for a general model which maybe takes into account the hardness of the material, or the grain size, etc. But if a general model does not exist, something for steel would be ok. $\endgroup$ Aug 24, 2018 at 19:01
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    $\begingroup$ Although I don't own it, Davim's Surface Integrity in Machining appears to address this topic and may be useful. $\endgroup$ Aug 24, 2018 at 19:11
  • $\begingroup$ Probably covered by Timoshenko... $\endgroup$
    – Solar Mike
    Aug 24, 2018 at 21:07
  • $\begingroup$ Not an answer,but, 25 years ago steel research labs( Valourec, Nippon, Sumitomo, etc.) could not calculate it for high strength steels ,eg. 90.000 psi yield. The object was to prepare test coupons with no cold work or residual stress. $\endgroup$ Aug 24, 2018 at 21:24


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