Modeling of Mechanical Residual Stresses in Micro-End Milling of Ti-6Al-4V Alloy

  • Y. Rahul
  • K. VipindasEmail author
  • Kattari Muni Sekhar
  • Jose Mathew
Conference paper
Part of the Lecture Notes on Multidisciplinary Industrial Engineering book series (LNMUINEN)


Wide range applications of micro-components make micromachining an important manufacturing method in industry. The distribution of machining-induced residual stresses has significant effects on the fatigue life, corrosion resistance, precision, and durability of parts. This study is focused on the modeling and validation of the residual stress induced in the workpiece after micro-end milling of Ti-6Al-4V. A coupled elasto-plastic model of mechanical stress inside the workpiece was developed to predict the residual stress. The contact between the cutter edge and the shear plane are considered a rolling contact which admits isotropic hardening only. In order to validate the developed residual stress model on the machined surface was evaluated by comparing the published literature result with similar cutting condition. It was found that the experimental and predicted values of both model and experimental results show hook-shaped distribution, with good agreement.


Micro-end milling Ti-6Al-4V Effective rake angle Residual stress Stress relaxation 



Authors would like to sincerely thank Department of Science and Technology (DST), Govt. of India and Centre for Precision Measurements And Nanomechanical Testing, Department of Mechanical Engineering, National Institute of Technology Calicut, for providing support to carry out this work under the scheme “Fund for improvement of Science and Technology” (No. SR/FST/ETI-388/2015).


  1. 1.
    Liu, X., Devor, R.E., Kapoor, S.G.: An analytical modeling for the prediction of minimum chip thickness in micro machining. ASME J. Manuf. Sci. Eng. 128, 474–481 (2008)CrossRefGoogle Scholar
  2. 2.
    Zeng, H., Yan, F., Peng, L., Zhou1, B.: An investigation of residual stresses in micro-end-milling considering sequential cuts effect. Int. J. Adv. Manuf. Technol. 91, 3619–3634 (2017)CrossRefGoogle Scholar
  3. 3.
    Ulutan, D., Alaca, B., Lazoglu, I.: Analytical modelling of residual stresses in machining. J. Mater. Process. Technol. 183, 77–87 (2007)CrossRefGoogle Scholar
  4. 4.
    Lazoglu, I., Ulutan, D., Alaca, B.E., Engine, S., Kaftanoglu, B.: An enhanced analytical model for residual stress prediction in machining. CIRP Ann. Manuf. Technol. 57, 81–84 (2008)CrossRefGoogle Scholar
  5. 5.
    Jacobus, K., Kapoor, S.G., Devor, R.E.: Machining-induced residual stress: experimentation and modeling. J. Manuf. Sci. Eng. 122, 20–31 (2000)CrossRefGoogle Scholar
  6. 6.
    Su, J.C., Young, K.A., Ma, K., Srivatsa, S., Morehouse, J.B., Liang, S.Y.: Modeling of residual stresses in milling. Int. J. Adv. Manuf. Technol. 65, 717–733 (2013)CrossRefGoogle Scholar
  7. 7.
    Zhipeng, P., Donald, S., Hamid, G., Steven, Y.: Residual stress prediction for turning of Ti-6Al-4V considering the microstructure evolution. Int. J. Mech. Sci. 23, 1–9 (2017)Google Scholar
  8. 8.
    Merwin, E., Johnson, K.: An analysis of plastic deformation in rolling contact. Proc. Inst. Mech. Eng. 177, 676–690 (1963)CrossRefGoogle Scholar
  9. 9.
    Fergani, O., Lazoglu, I., Makddem, A.: Analytical modeling of residual stress and the induced deflection of milled thin plate. Int. J. Adv. Manuf. Technol. 75, 455–463 (2014)CrossRefGoogle Scholar
  10. 10.
    Peng, F.Y., Dong, Q., Yan, R., Zhou, L., Zhan, C.: Analytical modeling and experimental validation of residual stress in micro-end-milling. Int. J. Adv. Manuf. Technol. 87, 3411–3424 (2016)CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringNational Institute of Technology CalicutKozhikodeIndia
  2. 2.Department of Mechanical EngineeringPandit Deendayal Petroleum UniversityGandhinagarIndia

Personalised recommendations