SUMMARY

Surface integrity of a machined component or the ability of a surface to meet the demands of a specific application is defined by several characteristics. The residual stress profile is often used as one of the characteristics since it has a direct effect on the fatigue life of a component. The purpose of this work is to fill in a significant void that exists in this research area. To date, no method is available that will enable one to engineer directly a specific residual profile in a machined component. This work will enable one to extract the appropriate cutting and tool geometry parameters from a desired residual stress profile in the workpiece. In prior research studies, several finite element and analytical models have been developed to help understand and characterize the effect of cutting parameters (i.e. feed, depth of cut, etc) and tool geometry (i.e. hone radius) on the residual stress profile. The main objective of this research will be met by developing an analytical model. This model will establish inverse relationships between critical parameters that were identified in previous work. Once implemented, the model will be validated using experimental data. This model will be compared to other previous models which take a forward approach into predicting residual stresses. By forward approach, one means predicting residual stresses from process conditions. This analytical model will provide an indispensable method to engineer residual stress in a machined component. It will enable customization of process and tool geometry parameters based on residual stress specifications. In a production environment, the model will help creating truly identical machined components. Furthermore, by having this added control on the surface integrity of part, a relatively new process such as hard turning could become a true alternative to grinding.