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<p>Residual stress developed on the surface is critical in influencing the surface integrity and fatigue behaviour of machined components in Ti6Al4V. This study investigates the variation in circumferential residual stress generated under various machining environments, such as dry cutting, vegetable oil-based hybrid nano-cutting fluid (VoBHNCF), vibration-assisted turning (VAT), Vortex tube-assisted cooling (VTAC), and vortex-cooled vibration-assisted turning (VC-VAT). Dry machining results in high tensile surface residual stress, whereas cooling and lubrication-assisted conditions shift the stress state to the compressive regime. VC-VAT produced better compressive circumferential surface residual stress (235.9&#xa0;MPa), highlighting its superior capability to reduce friction and thermal effect at the tool–work interface. VoBHNCF (197.5&#xa0;MPa), VTAC (186.3&#xa0;MPa), and VAT (174.2&#xa0;MPa) also exhibited moderate compressive circumferential surface residual stress due to their lubrication, cooling and intermittent cutting action, respectively.</p>

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Machining Induced Residual Stress in Ti6Al4V with Different Cooling Techniques

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • Srikanth Srimanthula,
  • Srinu Banoth,
  • Vamsi Krishna Pasam,
  • Naresh Kumar Maroju,
  • Venu Gopal Anne

摘要

Residual stress developed on the surface is critical in influencing the surface integrity and fatigue behaviour of machined components in Ti6Al4V. This study investigates the variation in circumferential residual stress generated under various machining environments, such as dry cutting, vegetable oil-based hybrid nano-cutting fluid (VoBHNCF), vibration-assisted turning (VAT), Vortex tube-assisted cooling (VTAC), and vortex-cooled vibration-assisted turning (VC-VAT). Dry machining results in high tensile surface residual stress, whereas cooling and lubrication-assisted conditions shift the stress state to the compressive regime. VC-VAT produced better compressive circumferential surface residual stress (235.9 MPa), highlighting its superior capability to reduce friction and thermal effect at the tool–work interface. VoBHNCF (197.5 MPa), VTAC (186.3 MPa), and VAT (174.2 MPa) also exhibited moderate compressive circumferential surface residual stress due to their lubrication, cooling and intermittent cutting action, respectively.