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Investigation of Residual Stresses Induced by Milling of Compacted Graphite Iron by x-ray Diffraction Technique

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Abstract

This study investigates the relationship between residual stresses, cutting parameters, and machining performance in the milling process of compacted graphite iron (CGI). X-ray diffraction (XRD) analysis is employed to measure residual stresses on the cast and milled surfaces, while cutting force modeling is utilized to calculate the tangential force, power, and active work. The results demonstrate that tensile residual stresses are predominant on the milled surfaces, attributed to the both mechanical and thermal loads generated during milling. By analyzing various cutting conditions, it is observed that lower feeds contribute to reduced plastic deformation, resulting in lower residual stress levels. Additionally, higher cutting speeds lead to higher temperatures, but due to the shorter machining time, heat accumulation is limited, resulting in higher residual stresses, especially at low feeds. At high feeds, residual stresses decreased as the cutting speed increased. The interplay between cutting parameters and residual stresses highlights the need for optimizing cutting conditions to enhance fatigue strength in CGI components. These findings provide valuable insights for process optimization and quality control in the milling of CGI materials.

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Source: M.E. Fitzpatrick, A.T. Fry, P. Holdway, F.A. Kandil, J. Shackleton, and L. Suominen, Determination of Residual Stresses by x-ray Diffraction —Issue 2, NPL, 2005

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Source: M.E. Fitzpatrick, A.T. Fry, P. Holdway, F.A. Kandil, J. Shackleton, and L. Suominen, Determination of Residual Stresses by x-ray Diffraction—Issue 2, NPL, 2005

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Acknowledgments

We are thankful for the support received from The Scientific and Technological Research Council of Türkiye.

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Authors and Affiliations

  1. Mechanical Engineering Department, Istanbul Technical University, 34437, Istanbul, Turkey

    Mehmet Emre Kara & Mustafa Bakkal

  2. Rail Transport Technologies Institute, TUBITAK, 41470, Kocaeli, Turkey

    Mehmet Emre Kara

  3. Mechanical Engineering Department, Isik University, 34980, Istanbul, Turkey

    Ali Taner Kuzu

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This invited article is part of a special topical issue of the Journal of Materials Engineering and Performance on Residual Stress Analysis: Measurement, Effects, and Control. The issue was organized by Rajan Bhambroo, Tenneco, Inc.; Lesley Frame, University of Connecticut; Andrew Payzant, Oak Ridge National Laboratory; and James Pineault, Proto Manufacturing on behalf of the ASM Residual Stress Technical Committee.

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Kara, M.E., Kuzu, A.T. & Bakkal, M. Investigation of Residual Stresses Induced by Milling of Compacted Graphite Iron by x-ray Diffraction Technique. J. of Materi Eng and Perform 33, 3801–3810 (2024). https://doi.org/10.1007/s11665-023-08904-3

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