Advertisement

Comprehensive investigation on the residual stress of large screws by whirlwind milling

  • Qin GuoEmail author
  • Jiaye Xie
  • Wenliang Yang
  • Youfeng Xu
  • Yulin Wang
ORIGINAL ARTICLE
  • 42 Downloads

Abstract

This study investigated the influence of cutting parameters on the residual stress obtained in whirlwind milling of AISI 52100 steel. Single-factor and Box-Behnken experiments were separately carried out. A prediction model of residual stress was developed on the basis of response surface methodology using experimental data. Results indicated that the cutting depth was the dominant factor, and the interaction between cutting speed and tool number was significant. The developed model could be effectively used to predict surface residual stress within high confidence. The optimum value and cutting condition were validated by confirmation experiments.

Keywords

Residual stress Response surface methodology Optimisation 

Notes

Funding information

This work was supported by the National Natural Science Foundation of China-Youth Found Project [grant number 51805243]; the Jiangsu Natural Science Foundation-Youth Found Project [grant number BK20160780]; and the PhD Research Startup Foundation of Nanjing Institute of Technology [grant number YKJ201518].

References

  1. 1.
    Choi Y (2017) Influence of rake angle on surface integrity and fatigue performance of machined surfaces. Int J Fatigue 94(part_P1):81–88.  https://doi.org/10.1016/j.ijfatigue.2016.09.013 CrossRefGoogle Scholar
  2. 2.
    Anthony XM, Manohar M, Madhukar PM, Jeyapandiarajan P (2017) Investigation of surface integrity during turning inconel 718. T Can Soc Mech Eng 41(3):387–394.  https://doi.org/10.1139/tcsme-2017-1027 CrossRefGoogle Scholar
  3. 3.
    Dogra M, Sharma V, Sachdeva A, Suri NM (2012) Finish hard turning of continuous and interrupted surfaces with cubic boron nitride (CBN) and coated carbide tools. Mater Manuf Process 27:523–530.  https://doi.org/10.1080/10426914.2011.593238 CrossRefGoogle Scholar
  4. 4.
    Klocke F, Brinksmeier E, Weinert K (2005) Capability profile of hard cutting and grinding processes. CIRP Ann 54:22–45.  https://doi.org/10.1016/s0007-8506(07)60018-3 CrossRefGoogle Scholar
  5. 5.
    Song SQ, Zuo DW (2014) Modelling and simulation of whirling process based on equivalent cutting volume. Simul Model Pract TH 42(3):98–106.  https://doi.org/10.1016/j.simpat.2013.12.011 MathSciNetCrossRefGoogle Scholar
  6. 6.
    Ni SY, Li Y, Deng S X (2012) Study on machining mechanism of internal whirling process for precise external thread and its tool profile design. J Mech Eng 48(7):193–198.  https://doi.org/10.3901/JME.2012.07.193 CrossRefGoogle Scholar
  7. 7.
    Jawahir IS, Brinksmeier E, M’Saobi R, Aspinwall DK, Outeiro JC, Meyer D, Umbrello D, Jayal AD (2011) Surface integrity in material removal processes: recent advances. CIRP Ann Manuf Technol 60:603–626.  https://doi.org/10.1016/j.cirp.2011.05.002 CrossRefGoogle Scholar
  8. 8.
    Wang W, Salvatore F, Rech J, Li J (2018) Comprehensive investigation on mechanisms of dry belt grinding on AISI52100 hardened steel. Tribol Int 121:310–320.  https://doi.org/10.1016/j.triboint.2018.01.019 CrossRefGoogle Scholar
  9. 9.
    Zhang F, Duan C, Wang M, Sun W (2018) White and dark layer formation mechanism in hard cutting of AISI52100 steel. J Manuf Process 32:878–887.  https://doi.org/10.1016/j.jmapro.2018.04.011 CrossRefGoogle Scholar
  10. 10.
    Arfaoui S, Zemzemi F, Tourki Z (2018) Relationship between cutting process parameters and white layer thickness in orthogonal cutting. Mater Manuf Process 33 (6):661–669.  https://doi.org/10.1080/10426914.2017.1364849 CrossRefGoogle Scholar
  11. 11.
    Hamdan A, Sarhan AAD, Hamdi M (2012) An optimization method of the machining parameters in high speed machining of stainless steel using coated carbide tool for best surface finish. Int J Adv Manuf Technol 58(1-4):81–91.  https://doi.org/10.1007/s00170-011-3392-5 CrossRefGoogle Scholar
  12. 12.
    Grove T, Tobias M (2017) Assessment of mechanical loads based on surface integrity analysis of machined components. CIRP Ann Manuf Technol 66:85–88.  https://doi.org/10.1016/j.cirp.2017.04.030 CrossRefGoogle Scholar
  13. 13.
    Fabre D, Bonnet C, Rech J, Mabrouki T (2017) Optimization of surface roughness in broaching. CIRP J Manuf Sci Technol 18:115–127.  https://doi.org/10.1016/j.cirpj.2016.10.006 CrossRefGoogle Scholar
  14. 14.
    Masmiati N, Sarhan AAD (2015) Optimizing cutting parameters in inclined end milling for minimum surface residual stress-Taguchi approach. Measurement 60:267–275.  https://doi.org/10.1016/j.measurement.2014.10.002 CrossRefGoogle Scholar
  15. 15.
    Umbrello D, Outeiro JC, M’Saoubi R, Jayal AD, Jawahir IS (2010) A numerical model incorporating the microstructure alternation for predicting residual stresses in hard machining of AISI 52100 steel. CIRP Ann Manuf Technol 59:113–116.  https://doi.org/10.1016/j.cirp.2010.03.061 CrossRefGoogle Scholar
  16. 16.
    Montagnat J, Sermesant M, Delingette H, Malandain G, Ayache N (2014) Review of residual stress modification techniques for extending the fatigue life of metallic aircraft components. Appl Mech Rev 67(1):010801.  https://doi.org/10.1115/1.4028160 CrossRefGoogle Scholar
  17. 17.
    Su JC, Young KA, Ma K, Srivatsa S, Morehouse JB (2013) Modeling of residual stresses in milling. Int J Adv Manuf Technol 65(5-8):717–733.  https://doi.org/10.1007/s00170-012-4211-3 CrossRefGoogle Scholar
  18. 18.
    Qin MY, Ye BY, Jia X, He AD (2013) Experimental investigation of residual stress distribution in pre-stress cutting. Int J Adv Manuf Technol 65(1-4):355–361.  https://doi.org/10.1007/s00170-012-4174-4 CrossRefGoogle Scholar
  19. 19.
    Salonitis K, Kolios A (2015) Experimental and numerical study of grind-hardening-induced residual stresses on AISI 1045 steel. Int J Adv Manuf Technol 79(9-12):1443–1452.  https://doi.org/10.1007/s00170-015-6912-x CrossRefGoogle Scholar
  20. 20.
    Dikshit MK, Puri AB, Maity A (2016) Optimization of surface roughness in ball-end milling using teaching-learning-based optimization and response surface methodology. Proc IMechE Part B: J Eng Manuf 231(14):2596–2607.  https://doi.org/10.1177/0954405416634266 CrossRefGoogle Scholar
  21. 21.
    Masmiati N, Sarhan AAD, Hassan MAN, Hamdi M (2016) Optimization of cutting conditions for minimum residual stress, cutting force and surface roughness in end milling of S50C medium carbon steel. Measurement 86:253–265.  https://doi.org/10.1016/j.measurement.2016.02.049 CrossRefGoogle Scholar
  22. 22.
    Coto B, Navas V G, Francisco OGD, Aranzabe A (2011) Influences of turning parameters in surface residual stresses in AISI 4340 steel. Int J Adv Manuf Technol 53(9-12):911–919.  https://doi.org/10.1007/s00170-010-2890-1 CrossRefGoogle Scholar
  23. 23.
    Guo Q, Ye L, Wang YL, Feng HT, Li Y (2014) Comparative assessment of surface roughness and microstructure produced in whirlwind milling of bearing steel. Mach Sci Technol 18:251–276.  https://doi.org/10.1080/10910344.2014.897843 CrossRefGoogle Scholar
  24. 24.
    Guo Q, Chang L, Ye L, Wang YL, Feng HT, Cao Y, Lian Q, Li Y (2013) Residual stress, nanohardness and microstructure changes in whirlwind milling of GCr15 steel. Mater Manuf Process 28:1047–1052.  https://doi.org/10.1080/10426914.2013.763963 CrossRefGoogle Scholar
  25. 25.
    He Y, Liu C, Li YF, Wang LX, Wang YL (2018) Transient thermal and analytical model of whirling process based on time-varying heat source in machining screw. J Mech Eng 54(15):180–190.  https://doi.org/10.3901/JME.2018.15.180 CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Qin Guo
    • 1
    Email author
  • Jiaye Xie
    • 1
  • Wenliang Yang
    • 1
  • Youfeng Xu
    • 1
  • Yulin Wang
    • 2
  1. 1.Industrial CenterNanjing Institute of TechnologyNanjingChina
  2. 2.School of Mechanical EngineeringNanjing University of Science and TechnologyNanjingChina

Personalised recommendations