Modeling and experimental validation of the surface residual stresses induced by hard machining of AISI H13 tool steel

Residual stresses induced by orthogonal cutting of AISI H13 tool steel were modeled and simulated using Finite Element (FE) method. A two-dimensional model using elastic-plastic material behavior, shear friction model and a physical chip separation criterion for chip formation were developed. To validate this model the predicted surface residual stresses were compared with those experimentally obtained using X-ray diffraction technique. Finally, the proposed FE model was applied to investigate the influence of flank tool wear and cutting regime parameters on surface residual stresses distribution in the machined surface of AISI H13 tool steel.