A novel hybrid predictive model and validation of unique hook-shaped residual stress profiles in hard turning

Hard turning produces a unique hook-shaped residual stress (RS) profile characterized by surface compressive RS and subsurface maximum compressive RS. However, how and why this unique RS profile is generally produced is not well understood. This paper presents a novel hybrid predictive model which simulates the process-induced unique RS profiles in hard turning. The key findings are: (a) ploughed depth is a major influencing factor in producing the machining-induced RS profile; (b) a unique hook-shaped RS profile is produced when the ploughing depth reaches a threshold (critical) value; and (c) the predicted hook-shaped RS profiles are validated experimentally.