Fatigue life prediction of ball-end milling surface based on residual stress solution

Fatigue life prediction of ball-end milling surface based on residual stress solution | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Fatigue life prediction of ball-end milling surface based on residual stress solution Wei Zhang, Guowen Tang, Minli Zheng, Junli Wei This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8705011/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract This paper analyzes the influence of residual stress on workpiece fatigue performance and on the prediction of ball-end milling surface life. An analytical model for the milling force and temperature field in ball-end milling is developed based on mechanisms of residual-stress generation. Using Hertz contact theory and the plane strain hypothesis, a thermal-mechanical coupling model for residual stress during loading, unloading, and release is constructed. A model for stress concentration factor K t is derived using Walter's method and surface topography parameters. The effect of residual stress on the cyclic load stress ratio is considered. A fatigue-life prediction model incorporating topography and residual-stress effects is established. The prediction model's accuracy is validated through simulation, X-ray detection, fatigue testing, and a comparison of experimental and theoretical results. Residual stress Surface morphology Stress concentration factor Fatigue life Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 04 May, 2026 Reviewers invited by journal 04 May, 2026 Editor assigned by journal 06 Feb, 2026 First submitted to journal 04 Feb, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8705011","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":634096197,"identity":"9a3ec094-5b54-4837-ad30-747a73ce684e","order_by":0,"name":"Wei Zhang","email":"data:image/png;base64,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","orcid":"","institution":"Harbin University of Science and Technology","correspondingAuthor":true,"prefix":"","firstName":"Wei","middleName":"","lastName":"Zhang","suffix":""},{"id":634096198,"identity":"f1a898f3-a87b-467d-8e34-3f0f691743ef","order_by":1,"name":"Guowen Tang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Guowen","middleName":"","lastName":"Tang","suffix":""},{"id":634096199,"identity":"671694d9-ade9-4807-a259-25de6f0deee6","order_by":2,"name":"Minli Zheng","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Minli","middleName":"","lastName":"Zheng","suffix":""},{"id":634096200,"identity":"d50d2c9d-b8dd-404e-9087-f91b194f6549","order_by":3,"name":"Junli Wei","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Junli","middleName":"","lastName":"Wei","suffix":""}],"badges":[],"createdAt":"2026-01-27 02:44:53","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8705011/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8705011/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":109073908,"identity":"966c21b5-d451-4ccd-9942-3448f260bf33","added_by":"auto","created_at":"2026-05-12 10:49:13","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1576308,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8705011/v1_covered_04aeaa31-fea8-4af9-967a-7ccb47b30ceb.pdf"}],"financialInterests":"","formattedTitle":"Fatigue life prediction of ball-end milling surface based on residual stress solution","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Residual stress, Surface morphology, Stress concentration factor, Fatigue life","lastPublishedDoi":"10.21203/rs.3.rs-8705011/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8705011/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis paper analyzes the influence of residual stress on workpiece fatigue performance and on the prediction of ball-end milling surface life. An analytical model for the milling force and temperature field in ball-end milling is developed based on mechanisms of residual-stress generation. Using Hertz contact theory and the plane strain hypothesis, a thermal-mechanical coupling model for residual stress during loading, unloading, and release is constructed. A model for stress concentration factor \u003cem\u003eK\u003c/em\u003e\u003csub\u003e\u003cem\u003et\u003c/em\u003e\u003c/sub\u003e is derived using Walter's method and surface topography parameters. The effect of residual stress on the cyclic load stress ratio is considered. A fatigue-life prediction model incorporating topography and residual-stress effects is established. 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