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Turning is a drastically favoured machining process for producing cylindrical components with required dimensions. Prediction of chip formation is essential when damages caused by chips are into consideration during machining. A high amount of residual stresses are generated in the machined component due to a large number of forces and temperature distribution during machining. The scope of this paper is to investigate the percentage of residual stresses induced in a component during the dry micro turning process. Hence, in this work, Inconel 718, A2024-T351, and AISI D2 (62HRC) are selected as a workpiece materials and WC as tool material, simultaneously comparison studies of chip morphology have been carried out. Also, cutting speed and power consumption were investigated experimentally by opting varied tool rake angles (positive, negative, and zero) and a depth of cut. Residual stresses, nose wear, and chip morphology were found experimentally while machining Inconel 718. From the simulation and experimental results obtained, one can adopt a suitable tool rake angle to minimise power consumption during the micro turning process which leads to a sustainable machining process.

Simulation and experimental study on effect of surface residual stresses in dry orthogonal micro turning sample