Title: Experimental investigation of the effect of tool geometry on residual stresses in high speed milling 7050-T7451 aluminium alloy

Authors: Xiaoming Huang; Jie Sun; Jianfeng Li

Addresses: Key Laboratory of High Efficiency and School of Mechanical Engineering, Clean Mechanical Manufacture, Shandong University, Jinan 250061, China ' Key Laboratory of High Efficiency and School of Mechanical Engineering, Clean Mechanical Manufacture, Shandong University, Jinan 250061, China ' Key Laboratory of High Efficiency and School of Mechanical Engineering, Clean Mechanical Manufacture, Shandong University, Jinan 250061, China

Abstract: The effects of tool geometry on residual stress distribution in the machined surface and subsurface of Al 7050-T751 were experimentally investigated. In the experiments, the residual stresses were measured by using X-ray diffraction technique in combination with electro-polishing technique. The results showed that the subsurface residual stresses generated in the end-milling cutting processes were compressive; and the nose radius, rake/relief angle and diameter of the solid end mill had a significant effect on residual stresses profiles. The dynamometer Kistler 9257A was used to measure the milling force, which was helpful to explain the phenomenon of machining induced residual stress.

Keywords: residual stresses; cutting tool geometry; end milling; cutting force; high speed milling; aluminium alloy; X-ray diffraction; electro-polishing; nose radius; rake-relief angle; solid end mill diameter.

DOI: 10.1504/IJSURFSE.2015.070813

International Journal of Surface Science and Engineering, 2015 Vol.9 No.4, pp.359 - 369

Received: 16 Apr 2014
Accepted: 20 May 2014
Published online: 28 Jul 2015 *

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