Influence of the cutting regime on the residual stresses generated by carbon steel milling

Abstract

All technological operations based on the material deformation generate residual stress. Milling is a complex process that involves effects like heat generation, plastic strains and residual stress. Some of the most important parameters used in the milling operation that influence the type of residual stress are: cutting speed, cutting feed and depth of cut. Residual stress distribution can affect the mechanical characteristics of the workpiece. The present paper is an experimental and theoretical study regarding the influence of the working parameters on residual stress distribution generated by milling. The experiments are carried out on carbon steel K945. The cutting regime is varied as: <i style="mso-bidi-font-style:normal">v</i> = 16 to 1036 m/min; <i style="mso-bidi-font-style:normal">f</i> = 375 to 1400 mm/min; depth of cut <i style="mso-bidi-font-style:normal">ap</i> = 0.15 to 0.5mm. A small cutting depth (equal to 0.15 mm) generated the lowest values of residual stress. The use of high cutting feed (equal to 1400 mm/min) lead to large variations of residual stress. Simulations by finite element method using AdvantEdge software have been conducted and compared with the experimental results. There is a good agreement between results of FE analysis and the experimental study.