Abstract
Micro-milling is widely used in aerospace and precision optical part manufacturing. Residual stress is an important index of surface integrity, which signally affects the performance of the micro-parts. This paper presents an analytical model to predict micro-milling residual stresses considering tool edge radius, material strengthening effects, and initial stress. A micro-milling cutting force prediction model is proposed, in which tool edge radius and material strengthening effects are taken into account. The imaginary heat source is utilized to estimate the temperature distribution in the workpiece. This model considers the prediction results of cutting force and temperature as thermomechanical loads experienced by the workpiece. Also, the effect of initial stress is taken into account during the estimation of residual stresses. After loading, unloading, and stresses release, the results of residual stresses in micro-milling are finally obtained. Both the micro-milling cutting force and residual stresses prediction results are validated by NAK80 steel on a three-axis ultra-precision machine. The predicted results capture the experiment results well in terms of distribution and value. Finally, the model is analyzed and discussed. The influences of tool edge radius, rake angle, feed per tooth, and spindle speed on residual stresses are preliminarily explored.
Similar content being viewed by others
References
Yu XX, Lau WS, Lee TC (1997) A finite element analysis of residual stresses in stretch turning. Int J Mach Tools Manuf 37:1525–1537
Jacobus K, DeVor RE, Kapoor SG (2000) Machining-induced residual stress: experimentation and modeling. J Manuf Sci Eng 122:20–31
El-Axir MH (2002) A method of modeling residual stress distribution in turning for different materials. Int J Mach Tools Manuf 42:1055–1063
Arunachalam RM, Mannan MA, Spowage AC (2004) Residual stress and surface roughness when facing age hardened Inconel 718 with CBN and ceramic cutting tools. Int J Mach Tools Manuf 44:879–887
Nasr MN, Ng E, Elbestawi MA (2007) Modelling the effects of tool-edge radius on residual stresses when orthogonal cutting AISI 316L. Int J Mach Tools Manuf 47:401–411
Jiang X, Li B, Yang J, Zuo X, Li K (2013) An approach for analyzing and controlling residual stress generation during high-speed circular milling. Int J Adv Manuf Technol 66(9-12):1439–1448
Shet C, Deng X (2003) Residual stresses and strains in orthogonal metal cutting. Int J Mach Tools Manuf 43:573–587
Sasahara H, Obikawa T, Shirakashi T (2004) Prediction model of surface residual stress within a machined surface by combining two orthogonal plane models. Int J Mach Tools Manuf 44:815–822
Outeiro JC, Umbrello D, Saoubi MR (2006) Experimental and numerical modelling of the residual stresses induced in orthogonal cutting of AISI 316L steel. Int J Mach Tools Manuf 46:1786–1794
Saini S, Ahuja IS, Sharma VS (2013) Modelling the effects of cutting parameters on residual stresses in hard turning of AISI H11 tool steel. Int J Adv Manuf Technol 5–8:667–678
Merwin JE, Johnson KL (1963) An analysis of plastic deformation in rolling contact. Proc, Institut Mech Eng, London 177(25):676–690
McDowell DL (1997) An approximate algorithm for elastic-plastic two-dimensional rolling/sliding contact. Wear 211:237–246
Ulutan D, Alaca BE, Lazoglu I (2007) Analytical modelling of residual stresses in machining. J Mater Process Technol 183:77–87
Su J (2006) Residual stress modeling in machining processes. George W. Woodruff School of Mechanical Engineering
Liang SY, Su J (2007) Residual stress modeling in orthogonal machining. CIRP Ann Manuf Technol 56:65–68
Su J, Young KA, Ma K, Srivatsa S, Morehouse JB, Liang SY (2013) Modeling of residual stresses in milling. Int J Adv Manuf Technol 65:717–733
Ji X, Zhang X, Liang SY (2014) Predictive modeling of residual stress in minimum quantity lubrication machining. Int J Adv Manuf Technol 70:2159–2168
Rao S, Shunmugam MS (2012) Analytical modeling of micro end-milling forces with edge radius and material strengthening effects. Mach Sci Technol 16:205–227
Zhou L, Peng FY, Yan R, Yao PF, Yang CC, Li B (2015) Analytical modeling and experimental validation of micro end-milling cutting forces considering edge radius and material strengthening effects. Int J Mach Tools Manuf 97:29–41
Jiang Y, Sehitoglu H (1994) An analytical approach to elastic-plastic stress analysis of rolling contact. J Tribol 116:577–587
Komanduri R, Hou ZB (2000) Thermal modeling of the metal cutting process: part I—temperature rise distribution due to shear plane heat source. Int J Mech Sci 42:1715–1752
Ozlu E, Budak E, Molinari A (2009) Analytical and experimental investigation of rake contact and friction behavior in metal cutting. Int J Mach Tools Manuf 49:865–875
Merchant ME (1945) Mechanics of the metal cutting process II plasticity conditions in orthogonal cutting. J Appl Phys 16:318–324
Manjunathaiah J, Endres WJ (2000) A new model and analysis of orthogonal machining with an edge-radiused tool. J Manuf Sci Eng 122:384–390
Johnson GR, Cook WH (1983) A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. Proceedings, The Hague, Netherlands
Joshi SS, Melkote SN (2004) An explanation for the size-effect in machining using strain gradient plasticity. J Manuf Sci Eng 126:679–684
Nix WD, Gao H (1998) Indentation size effects in crystalline materials: a law for strain gradient plasticity. J Mech Phys Solids 46:411–425
Gao H, Huang Y (2001) Taylor-based nonlocal theory of plasticity. Int J Solids Struct 38:2615–2637
Armarego E, Brown RH (1969) The machining of metals. Proceedings, Prentice-hall Inc, Englewood Cliffs
Waldorf DJ, DeVor RE, Kapoor SG (1998) A slip-line field for ploughing during orthogonal cutting. J Manuf Sci Eng 120:693–699
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Peng, F.Y., Dong, Q., Yan, R. et al. Analytical modeling and experimental validation of residual stress in micro-end-milling. Int J Adv Manuf Technol 87, 3411–3424 (2016). https://doi.org/10.1007/s00170-016-8697-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-8697-y