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A Model for Residual Stress in the Dry Turning of Duplex Stainless Steels

Machining induced tensile residual stress of components made from Duplex Stainless Steel (DSS) is a major factor affecting their functional performance. This work used a multi-regression modeling approach for establishing the relationship amongst process parameters of turning operation and residual stress for standard DSS components. Four turning parameters namely, cutting speed, cutting depth, rate of feed & radius of tool nose were varied. Each of the selected parameters had three levels of values. The influence of these variations on residual stress was noted. Experiments were performed using Definitive Screening Design (DSD). Surface residual stress was measured using X-ray diffraction method. Step Wise regression approach with forward selection of terms and alpha value of 0.25 resulted in a quadratic model with R square value of 94.8 %. Validation experiment with new specimens yielded prediction accuracy of 88%.