of Achievements in Materials

and Manufacturing Engineering

VOLUME 24
ISSUE 1
September
2007

Residual stresses modelling in hard

turning and its correlation with the
cutting forces
G.F. Batalha c,*
co-operating with

S. Delijaicov a,b, J.B. Aguiar c, E.C. Bordinassi b, M. Stipkovic Filho b,c

a Department of Mechanical Engineering Faculdade de Engenharia Industrial
do Centro Universitrio da FEI, Av. Humberto de Alencar Castelo Branco,
397209580.901, S. Bernardo do Campo, SP, Brazil
b Department of Mechanical Engineering Escola de Engenharia Mau Instituto
Mau de Tecnologia, Praa Mau, 0109580.900, So Caetano do Sul, SP, Brazil
c Department of Mechatronics and Mechanical Systems Engineering - Escola Politcnica da
Universidade de So Paulo, Av. Prof. Mello Moraes, 223105508.970, So Paulo, SP, Brazil
* Corresponding author: E-mail address: gilmar.batalha@poli.usp.br
Received 15.04.2007; published in revised form 01.09.2007

Manufacturing and processing

Abstract
Purpose: This paper aims to study the cutting parameters influence (cutting speed, feed rate, cutting depth and
tool radius nose) on the cutting forces (cutting force, feed rate cutting force and penetration cutting force) as
well as on the residual stresses, in conical bearings made of steel DIN 100 CrMn6 hardened (62 HRc), searching
correlations between the residual stresses and the cutting forces.
Design/methodology/approach: A complete factorial planning was used to establish the correlations. At the
same time, the cutting parameters influence in the microstructure of the material and its correlation with the
residual stress was studied. A turning center machine and CBN inserts was employed for the tests. To the cutting
force measurements was carried out using a piezoelectric dynamometer. The residual stresses measurements
were carried out by X-ray diffractometry.
Findings: The penetration cutting force was the most important factor in the residual stress generation, and it
was influenced by the feed rate and the cutting depth. A correlation between the cutting depth and the residual
stresses was established. The results do not showed any changes in the microstructure of the material, even when
the greater cutting parameters were used.
Research limitations/implications: The residual stress is one of the major causes of failures in bearings by
contact fatigue, keeping this on mind, this work helps the developer to select correct cutting parameters in order
to increase the machined workpiece life in service.
Originality/value: This work were based on the real components (conical bearings), real cutting conditions and
with these results were possible to make greater improvements in the manufacturing and in the quality of the
studied parts.
Keywords: Machining; Turning; Hard turning; Residual stress

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Copyright by International OCSCO World Press. All rights reserved. 2007

Manufacturing and processing

1. 
Introduction
1. Introduction
Unlike the conventional process, the hard steel turning
introduces compressive residual stresses in surface and in the
subsurface of the work piece, increasing with this its fatigue
resistance [1], what is particularly beneficial to the applications in
rotational elements under external loads, as the bearings. The
reference [2] affirms that the high temperatures and the fast
cooling in the cutting area can introduce a temper treatment in
surface material, generating a fine layer of tempered martensite
well-known as white layer [3-6]. As a consequence of this
transformation, below this layer, another one can be formed, the
black layer, of lower hardness and under tension stress state.
According to references [6-8], one of the main factors of this
structure generation in the surface and in the sub-surface of the
machined steel, is the tool wear, which is a critical factor in the
increase of the temperature in the cutting area. Regarding the
influence on the components of the cutting forces, in agreement
with reference [10-12] the high-speed turning process of
hardened materials differs of the conventional process, once in the
first, the cutting force penetration is the bigger one, while in the
second, its the cutting force.
The machining also introduces residual stresses on the
material surfaces, and its an important factor to be analyzed
specially on the recurrent solicitations where it has greater
importance. Depending of its value, the life of a bearing can be
increased in more than 30 % [12]. So many studies have been
conducted in this area, some of then recent [13-24].
This work, tried to investigate the existence of a relationship
between the cutting forces, particularly by penetration force, with
the residual stresses introduced in the surface of one machined
piece (internal ring of a conical bearing), of steel DIN 100CrMn6
and with hardness between 60 and 64 HRc.
The tests were planned by a statistical analysis according to
the DOE (Design of experiments) methodology, reducing with
that, the costs and the expended execution time of the tests [29].
The analysis was made being taken in consideration the influence
of the cutting parameters effects (cutting speed, feed rate, cutting
depth and tool nose radius), on the introduced residual stresses
and the cutting force.

Insert with VNMA 160404(08)BCN 200 geometry, with 4

cutting faces, covered with ceramic and TiAlN base,
Sumitomo;
x Machine turning center: CNCOKUMA LB300;
x Piezoelectric dynamometer PCB-206A1, with maximum scale
measurements of 4.45 kN for the feed rate cutting force and
cutting force, and 5.87 kN for penetration cutting force;
x Acquisition signal system data, HBM Spider 8 operating with
the Catman 4 data acquisition software, under a frequency of
200 Hz;
The tests were conducted without cutting fluid utilization and
the used cutting parameters were: cutting speed: 150 and 210
m/mim; feed rate: 0.05 and 0.15 mm/rev; cutting depth: 0.05 and
0.20 mm and tool nose radius: 0.4 and 0.8 mm.
The internal ring of the conical bearing used on the tests is
illustrated in the Fig. 1.
For the residual stresses measurements, the X - ray diffraction
technique was used, with the sin2\ method with the variation of
the measurement angle from - 60 to + 60, being irradiated CrK
in the cristalografics planes (2 1 1). The used equipment was the
DMAX model from RIGAKUI. The obtained residual stresses
values were circunferentials, that is, in the tangential direction to
the bearing ring cone, and sixteen bodies of machined tests were
measured (complete factorial planning without replicate) and
another one body in the precedent state to the machining [25-28].
Some metallographic analyses were conducted in some pieces
before machining and the microstructure was typically formed by
martensite with high carbon content and dispersed primary
carbonetes in all the mass, with of 5 to 10% of retained austenite.
x

2. 
Experimental
procedure
2. Experimental
Procedure
The experimental planning was elaborated to be accomplished
through a complete factorial analysis with one replicate in two
levels and four factors (cutting speed, feed rate, cutting depth, tool
nose radius), with the objective of evaluating which were the most
significant factors and its respective interactions in the answers:
cutting forces (cutting force, feed rate cutting force and
penetration force), residual stress and microstructure of the
material.
The used items in the experiments were [25]:
x 32 bodies test of DIN 100 CrMn6 steel, temper and quenched
with 60 to 64 HRc hardness. The chemical composition of the
material was: 0.93 C, 0.49 Si, 1.02 Mn, 1.48 Cr, 0.018 P,
0.012 S, 0.12 Ni, and 0.15 Cu.

Fig. 1. Internal conical bearing ring used on the tests

READING DIRECT: www.journalamme.org

351

Journal of Achievements in Materials and Manufacturing Engineering

Volume 24 Issue 1 September 2007

Table 1.
Cutting force measurements
Test

cs [m/min]

f [mm/r]

p [mm]

radius [mm]

Ff [N]

Fc [N]

Fp [N]

Resultant [N]

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210
150
210

0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15
0,05
0,05
0,15
0,15

0,05
0,05
0,05
0,05
0,2
0,2
0,2
0,2
0,05
0,05
0,05
0,05
0,2
0,2
0,2
0,2
0,05
0,05
0,05
0,05
0,2
0,2
0,2
0,2
0,05
0,05
0,05
0,05
0,2
0,2
0,2
0,2

0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,8

26,3
17,9
50,3
50,3
37,3
38,1
74,7
63,3
30,8
31,3
62.1
58,7
47,7
52,2
103,6
86,8
23,6
19,1
53,3
50,3
37,7
40
76,5
68,2
30,3
31,2
56,7
59,8
44,2
49,2
102,9
92,9

33,9
17,3
71,2
75,4
65,1
64,1
146,7
142.1
33P4
31,3
75,9
76,3
60,1
62,9
162,6
127,7
32,3
21,6
75,9
74,4
63,3
67,9
147
131,6
33,8
27,7
76,3
70,1
62,9
62,9
160,4
143,2

59,9
28,5
91,8
91,9
137,1
134,3
222,6
203,2
51,4
52,2
93,3
90,5
104,3
114,9
228,9
163,5
53,6
33,4
98,8
91,2
132,8
144,1
219,9
195,2
57,5
46,7
86,3
93,9
104,4
111,3
243,9
176,8

73,68
37,84
126,6
129,08
156,29
153,61
276,86
255,91
68,6
68,44
135,36
132.13
129,48
141,01
299,28
224,89
66,88
44,12
135,51
128
151,87
164,24
275,35
245,1
73,26
62,62
128,39
131,56
129,65
136,98
309,52
245,75

3. 
Experimental
results
3. Experimental
results
The Table 1 indicates the obtained values for the cutting
forces measurements.
It was adopted, for the experiment analysis, a complete
factorial planning of four factors and two levels without
replication, in a total of 32 measurements for the penetration
cutting force and for the resulting cutting force, for the fact of
being the first, the portion that more contributes to the
development of the residual stresses in the piece during the
machining, and for the second as a form to involve the three
cutting force measurements, since it could have some influence
from the other cutting forces in the residual stresses generation.
It can be observed at the Fig. 2 and 3 (the effects on the
penetration cutting forces and resultant cutting forces), that the
significant effects are the same ones, that is, the feed rate and the
cutting depth, what allowed continuing with the research only
using the cutting penetration force.

352

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Fig. 2. Main effects plot for the penetration cutting force

G.F. Batalha, S. Delijaicov, J.B. Aguiar, E.C. Bordinassi, M. Stipkovic Filho

Manufacturing and processing

Fig. 3. Main effects plot for the resultant cutting force

The Table 2 shows residual stresses values at a
circumferential direction on the machined parts, tested according
to the methodology early described [25]. It is observed that in all
of the measurements, the residual stresses are compressive. The
measurements before machining has resulted in tensile residual
stresses levels of: +76, +95 and +50 MPa.

Fig. 4. Main effects plot for the residual stresses

The metallographic analysis made on the 32 work pieces, with
objective of detecting the presence of the white layer at machine
surface, showed that for these machined conditions the superheat
and consequent re-quenched didn't happen here under these
conditions. The microstructure of the metal practically didn't lose
hardness, staying as tempered martensite with primary carbides
dispersed into the whole metal. The Fig. 5 shows an example.

Table 2.
Residual stresses measurements
Test

cs
f
P
[m/min] [mm/v] [mm]

radius
[mm]

Fz
[N]

Residual
stresses [MPa]

150

0,05

0.05

0,4

57

-947

210

0.05

0.05

0.4

31

-586

150

0,15

0.05

0.4

95

-862

210

0.15

0.05

0.4

92

-990

150

0.05

0,2

0.4

135

-479

210

0.05

0,2

0.4

139

-295

150

0,15

0.2

0.4

221

-811

210

0.15

0.2

0.4

199

-977

150

0.05

0.05

0.8

54

-631

10

210

0.05

0.05

0.8

49

-443

11

150

0.15

0.05

0.8

90

-875

12

210

0,15

0.05

0.8

92

-901

13

150

0.05

0.2

0.8

104

-421

14

210

0.05

0.2

0.8

113

-363

15

150

0.15

0.2

0.8

235

-718

16

210

0,15

0.2

0.8

170

-529

The Fig. 4 shows the main effects plot for residual stresses.
The main effects are the same as the showed on the cutting force
analysis that means: the feed rate and the cutting depth. So, it is
possible to correlate the residual stresses with these parameters.

(a) 200 X

(b) 400 X

Fig. 5. Machined surface: transversal section microstructure

4. 
Analysis
of results
the results
4. Analysis
of the
The factorial analyses relatively to the cutting forces, showed
similarity results for the penetration force (Fz) and to resultant of
the cutting forces (Res), with the variances, and in relation to the
most significant factors of influence in the process.
As the non significant effects are zero or aleatory distributed
around the zero, the respective normal pareto graph indicate that,
for an confidenc level of 95% ( 1.96 . V), the feed rate, cutting
depth and its interaction are the most significant factors, for the
penetration cutting and for the resultant force.
The penetration force (Fz) can be adopted as the cutting force
component that is possibly correlated with the residual stresses.
The cutting speed and the tool nose radius do not have influence
on the penetration force. By other side, an increase in the feed rate
and in the penetration force, increase the mean values of the
penetration forces.
The increase on the feed rate induces a larger volume of the
cut material in a same unit of time, besides establishing a dynamic
effect on the cutting forces. In the same way the increase on the

Residual stresses modelling in hard turning and its correlation with the cutting forces

353

Journal of Achievements in Materials and Manufacturing Engineering

cutting depth make a larger volume of the removed material.

These facts explain the most significance of these factors under
the penetration force.
The factorial analysis also indicates that the cutting speed do
not affect the other factors with relationship to the influence on
the penetration force. In the same way it happens with the tool
nose radius. On the other hand, it is noticed that the interaction
between feed rate and cutting depth has some influence in the
penetration force.
Based on the experimental values and the respective factorial
analysis, an empirical model was proposed to describe the
dependence of the penetration force (Fz) with the feed rate (f), and
the cutting depth (p), at a confidence level of 90 % on the
identification of the significant factors of the process.
Being considered the estimate coefficients for the penetration
force (Fz) obtained in the factorial planning, a multiple regression
of this force can be predicted through Eq. 1:
Fz = 6.96 + 317.35 . f + 375.73 . p + 2515.42 . f . p

Volume 24 Issue 1 September 2007

confidence level of 90 % in the identification of the significant

factors of the process.

V = - 630.54 2172.50 . a + 2128.33 . p + 7600 . a . p

(4)

Another model that it can be proposed, in agreement with the

tendency of the current researches, is the potential model
according with Eq. 5.

V = 2156.5 . a 0.7 + 47.4 . p 0.7

(5)

Using the Eq. 1 and 4 for the feed rate and cutting depth
factors and calculating the relation the residual stresses and the
penetration cutting, is possible to obtain the graphs illustrated on
the Fig. 7.

(1)

Another model that can be proposed, in agreement with the

trend line of current researches, could be a power law, such as the
pattern of Eq. 2.
Fz = x. a y + z. p w

(2)

Where x, y, z and w are constants.

Through mathematical software the previous equations can
bee optimized increasing this reliability. The Eq. 3 shows the one
that presents smaller deviation in relation to the experimental
values, between the all analyzed equations:
Fz = - 12.37 . f - 0,75 + 434 . p - 0,35

(3)

The Fig. 6 shows the graphs of the Eq. 3.

Fig. 7. Relation between the residual stresses and the penetration

force as function of the feed rate and cutting depth
Applying the ratio (Residual Stress/Penetration Force) to the
factorial analysis for two factors (feed rate (mm/rev) and cutting
depth (mm) under two levels of the experiment, its possible to
identify a linear empirical model for this relationship; Applying
the estimated coefficients, resulted in the Eq. 6:

Vres = 20.56 57.77 . f - 87.77 . p + 31.33 . f . p

(6)

The Fig. 8 shows the graph for the Eq. 6.

Fig. 6. Penetration force as function of feed rate and cutting depth

The factorial analysis for the residual stresses revealed that,
the most significant factors of the experiment are the feed rate (f)
and the cutting depth (p), as can be observe in the Fig. 4, and that
to have high compression residual stresses is demanded to
machining with low values of cutting depths, high feed rate values
and low values for the tool nose radius.
Based on the experimental values and in the respective
factorial analysis, the Eq. (4) shows the dependence of the
residual stresses with the feed rate (f) and the cutting depth (p), a

354

Occasional paper

Fig. 8. Relationship between the residual stresses and the

penetration force
The Eq. 3 and 5 were treated in terms of level curves and
represented by the Fig. 9, 10 and 11.

G.F. Batalha, S. Delijaicov, J.B. Aguiar, E.C. Bordinassi, M. Stipkovic Filho

Manufacturing and processing

Fig. 9. Level curve for the variation of the penetration force with
the feed rate and the cutting depth.

The penetration force grows with the increase of the feed rate
and the cutting depth.
To resultant cutting forces behaves in the same way that by
penetration force, with relationship to the feed rate and cutting
depth parameters.
It was not possible to find structural transformations on the
current phases and consequent white layers formation in the
domain of the experiments of this work.
The relationship between the feed rate and cutting depth with
the penetration force could be described through linear and potential
equations.
The feed rate and cutting depth were the most significant
factors on the circunferentials residual stresses introduced in the
surface of the bodies tests.
The residual stresses were of compression in all the bodies test
measurements, in the domain of the experiments of this work.
The residual stresses are so much more compressive as larger
the feed rate and the and smaller the cutting depths parameters.
The obtained experimental results allowed the proposition of
equations of the linear and potential type.
A correlation between the residual stress and the penetration
force was established.

Acknowledgements
Acknowledgements
The authors would like to thanks the FAG Bearings-Brazil.
Fig. 10. Level curve for the variation of the residual stresses with
the feed rate and the cutting depth.

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Fig. 11. Level curve for the correlation between the residual
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[6]
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5. Conclusions
5. Conclusions

[8]

The measured values of the penetration force were always the

largest between the cutting forces, and the feed rate and cutting
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G.F. Batalha, S. Delijaicov, J.B. Aguiar, E.C. Bordinassi, M. Stipkovic Filho