Springer Nature is making SARS-CoV-2 and COVID-19 research free. View research | View latest news | Sign up for updates

Experimental investigation of residual stress distribution in pre-stress cutting

  • 391 Accesses

  • 12 Citations


This paper presents an analysis and experimental study on the formation and distribution of machined surface residual stress in pre-stress cutting. In the first component of the paper, the mechanical and thermal effect on residual stress is analysed. The results show that machined harden layer and cutting heat transfer conditions are crucial to form residual stress in a machined surface. Residual stress has three kinds of distributions in different mechanical and thermal conditions: tensile stress, compressive stress and tensile–compressive stress. If pre-stress is applied, it would facilitate residual compressive stress in the machined surface effectively; its action is analysed with an experimental study. The experiment is carried out by hardened 40Cr alloy steel turning with different tool rounds and pre-stress loading; the results obtained in this study indicate that the tool round would redound to generate residual compressive stress in the machined surface and affect the residual stress distribution significantly, whilst pre-stress load can affect the magnitude of residual stress actively, but does not for its distribution. It is found that the experimental results of residual stress distribution are consistent with the theoretical analysis.

This is a preview of subscription content, log in to check access.


  1. 1.

    Ko TJ, Kim HS (2001) Surface integrity and machineability in intermittent hard turning. Int J Adv Manuf Technol 18(3):168–175

  2. 2.

    Mamalis AG, Kundrak J, Gyani K (2002) On the dry machining of steel surfaces using superhard tools. Int J Adv Manuf Technol 19(3):157–162

  3. 3.

    Sasahara H (2005) The effect on fatigue life of residual stress and surface hardness resulting from different cutting conditions of 0.45 %C steel. Int J Machine Tools Manuf 45(2):131–136

  4. 4.

    Zong WJ, Li D, Cheng K, Sun T, Liang YC (2007) Finite element optimization of diamond tool geometry and cutting-process parameters based on surface residual stresses. Int J Adv Manuf Technol 32(7–8):666–674

  5. 5.

    Shet C, Deng X (2003) Residual stresses and strains in orthogonal metal cutting. Int J Machine Tools Manuf 43(6):573–587

  6. 6.

    Tsuchida K, Kawada Y, Kodama S (1975) A study of the residual stress distributions by turning. Bull Jpn Inst Met 18:123–130

  7. 7.

    Umbrello D (2011) Influence of material microstructure changes on surface integrity in hard machining of AISI 52100 steel. Int J Adv Manuf Technol 54(9–12):887–898

  8. 8.

    Afazov SM, Becker AA, Hyde TH (2010) Effects of micro-stresses from machining and shot-peening processes on fatigue life. Int J Adv Manuf Technol 51(5–8):711–722

  9. 9.

    Tang L, Huang J, Xie L (2011) Finite element modeling and simulation in dry hard orthogonal cutting AISI D2 tool steel with CBN cutting tool. Int J Adv Manuf Technol 53(9–12):1167–1181

  10. 10.

    Bruni C, Celeghini M, Geiger M, Gabrielli F (2007) A study of techniques in the evaluation of springback and residual stress in hydroforming. Int J Adv Manuf Technol 33(9–10):929–939

  11. 11.

    Henriksen EK (1951) Residual stresses in machined surfaces. J Am Soc Mech Eng Trans 73(1):69–76

  12. 12.

    Coto B, Navas VG, Gonzalo O, Aranzabe A, Sanz C (2011) Influences of turning parameters in surface residual stresses in AISI 4340 steel. J Adv Manuf Technol 53(9–12):911–919

  13. 13.

    Hua J, Umbrello D, Shivpuri R (2006) Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel. J Mater Process Technol 171(2):180–187

  14. 14.

    Liu M, Takagi J-I, Tsukuda A (2004) Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel. J Mater Process Technol 150(3):234–241

  15. 15.

    Ghanem F, Fredj NB, Sidhom H, Braham C (2011) Effects of finishing processes on the fatigue life improvements of electro-machined surfaces of tool steel. Int J Adv Manuf Technol 52(5–8):583–595

  16. 16.

    Habak M, Lebrun JL (2011) An experimental study of the effect of high-pressure water jet assisted turning (HPWJAT) on the surface integrity. Int J Machine Tools Manuf 51(9):661–669

  17. 17.

    Zhou Z, Guo D (1987) Pre-stressed machining. Proceedings of the 9th ICPR, vol I, Cincinnati, USA, pp 257–263

  18. 18.

    Nan-hua H, Ze-hua Z, Cen-zhou C (1994) Theoretical analysis of pre-stress machined surface residual stresses. Journal of South China University of Technology 22(2):129

  19. 19.

    Rui-tao P, Bang-yan Y, Xin-zi T (2008) Research of residual stress and surface morphology in pre-stress hard machining. Journal of South China University of Technology 36(4):6–9

  20. 20.

    Barash MM, Schoech WJ (1970) A semi-analytical model of the residual stress zone in orthogonal machining. Proceedings of the 11th International M. T. D. R. Conference, London, p 9

  21. 21.

    Thiele JD, Melkote SN (1999) Effect of tool edge geometry on workpiece sub-surface deformation and through-thickness residual stresses for hard-turning of AISI 52100 steel. Society of Manufacturing Engineers (MR99-167), pp 1–6

Download references

Author information

Correspondence to Qin Meng-yang.

Rights and permissions

Reprints and Permissions

About this article

Cite this article

Meng-yang, Q., Bang-yan, Y., Xiong, J. et al. Experimental investigation of residual stress distribution in pre-stress cutting. Int J Adv Manuf Technol 65, 355–361 (2013). https://doi.org/10.1007/s00170-012-4174-4

Download citation


  • Residual stress
  • Surface quality
  • Pre-stress cutting
  • Fatigue life