Abstract
The distribution of machining-induced residual stresses has significant effects on the fatigue life, corrosion resistance, and precision durability of parts. An analytical model is presented to reveal the evolution regularity of residual stresses in workpiece for micro-end-milling. Considering the characteristics of tool rotation and interrupted cutting, the process of cutting entry and exit of each flute is treated as one cut, and sequential cuts effect is taken into account in the proposed model. The stress state caused by the previous cut is taken as the initial condition for the current cut. In order to improve the prediction efficiency, a new methodology which supposes the tool makes reverse movement is developed to determine the initial cutter position for residual stress calculation. The theoretical model is validated by machining NAK80 steel under different flank wear widths on a 3-axis ultra-precision micro-milling machine. Residual stresses are tested by means of X-ray diffraction. The computed results show that residual stresses are compressive and present a hook-shaped distribution, which is consistent with experimental results. Moreover, the effects of feed rate and radial depth of cut on residual stresses are theoretically investigated. This work can be further applied to optimize cutting conditions to achieve better surface integrity.
Similar content being viewed by others
References
Navas VG, Gonzalo O, Bengoetxea I (2012) Effect of cutting parameters in the surface residual stresses generated by turning in AISI 4340 steel. Int J Mach Tools Manuf 61(4):48–57
Sun J, Guo YB (2009) A comprehensive experimental study on surface integrity by end milling Ti–6Al–4 V. J Mater Process Technol 209(8):4036–4042
El-Wardany TI, Kishawy HA, Elbestawi MA (2000) Surface integrity of die material in high speed hard machining, Part 2: microhardness variations and residual stresses. J Manuf Sci Eng 122(4):632–641
Rao B, Dandekar CR, Shin YC (2011) An experimental and numerical study on the face milling of Ti–6Al–4 V alloy: tool performance and surface integrity. J Mater Process Technol 211(2):294–304
Liu CR, Guo YB (2000) Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer. Int J Mech Sci 42(6):1069–1086
Nasr MNA (2015) Effects of sequential cuts on residual stresses when orthogonal cutting steel AISI 1045. Procedia CIRP 31:118–123
Ee KC, Dillon OW, Jawahir IS (2005) Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius. Int J Mech Sci 47(10):1611–1628
Zhao H, Liu C, Cui T, Tian Y, Shi C, Li J, Huang H (2013) Influences of sequential cuts on micro-cutting process studied by smooth particle hydrodynamic (SPH). Appl Surf Sci 284(11):366–371
Li JL, Jing LL, Chen M (2009) An FEM study on residual stresses induced by high-speed end-milling of hardened steel SKD11. J Mater Process Technol 209(9):4515–4520
Merwin JE, Johnson KL (1963) An analysis of plastic deformation in rolling contact. Proc Inst Mech Eng 177(1):676–690
Jiang Y, Sehitoglu H (1994) An analytical approach to elastic-plastic stress analysis of rolling contact. J Tribol 116(3):577–587
Ulutan D, Alaca BE, Lazoglu I (2007) Analytical modelling of residual stresses in machining. J Mater Process Technol 183(1):77–87
Yan L, Yang W, Jin H, Wang Z (2012) Analytical modeling of the effect of the tool flank wear width on the residual stress distribution. Mach Sci Technol 16(2):265–286
McDowell DL (1997) An approximate algorithm for elastic-plastic two-dimensional rolling/sliding contact. Wear 211(2):237–246
Liang SY, Su JC (2007) Residual stress modeling in orthogonal machining. CIRP Ann Manuf Technol 56(1):65–68
Ji X, Zhang X, Liang SY (2014) Predictive modeling of residual stress in minimum quantity lubrication machining. Int J Adv Manuf Technol 70(9–12):2159–2168
Agrawal S, Joshi SS (2013) Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel. J Manuf Process 15(1):167–179
Fuh KH, Wu CF (1995) A residual-stress model for the milling of aluminum alloy (2014-T6). J Mater Process Technol 51(1):87–105
Ma Y, Feng P, Zhang J, Wu Z, Yu D (2016) Prediction of surface residual stress after end milling based on cutting force and temperature. J Mater Process Technol 235:41–48
Yang D, Liu Z, Ren X, Zhuang P (2016) Hybrid modeling with finite element and statistical methods for residual stress prediction in peripheral milling of titanium alloy Ti-6Al-4 V. Int J Mech Sci 108:29–38
Su JC, Young KA, Ma K, Srivatsa S, Morehouse JB, Liang SY (2013) Modeling of residual stresses in milling. Int J Adv Manuf Technol 65(5–8):717–733
Zhou R, Yang W (2016) Analytical modeling of residual stress in helical end milling of nickel-aluminum bronze. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9145-8
Denkena B, Nespor D, Böß V, Köhler J (2014) Residual stresses formation after re-contouring of welded Ti-6Al-4 V parts by means of 5-axis ball nose end milling. CIRP J Manuf Sci Technol 7(4):347–360
Lin S, Peng F, Wen J, Liu Y, Yan R (2013) An investigation of workpiece temperature variation in end milling considering flank rubbing effect. Int J Mach Tools Manuf 73:71–86
Jin X, Altintas Y (2012) Prediction of micro-milling forces with finite element method. J Mater Process Technol 212(3):542–552
Lin ZC, Lin YY, Liu CR (1991) Effect of thermal load and mechanical load on the residual stress of a machined workpiece. Int J Mech Sci 33(4):263–278
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
Gao H, Huang Y (2001) Taylor-based nonlocal theory of plasticity. Int J Solids Struct 38(15):2615–2637
Joshi SS, Melkote SN (2004) An explanation for the size-effect in machining based on strain gradient plasticity. J Manuf Sci Eng 126(4):679–684
Altintas Y (2012) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge University Press, Cambridge
Manjunathaiah J (1998) Analysis and new model for the orthogonal machining process in the presence of edge-radiused (non-sharped) tools (Ph.D. dissertation). The University of Michigan, USA
Basuray PK, Misra BK, Lal GK (1977) Transition from ploughing to cutting during machining with blunt tools. Wear 43(3):341–349
Waldorf DJ, Devor RE, Kapoor SG (1998) A slip-line field for ploughing during orthogonal cutting. J Manuf Sci Eng 120(4):693–699
Waldorf DJ, Kapoor SG, Devor RE (1999) Worn tool forces based on ploughing stresses. Transactions of the North American Manufacturing Research Institution of SME 27:165–170
Johnson KL (1987) Contact mechanics. Cambridge University Press, Cambridge
Jacobus K, Devor RE, Kapoor SG (2000) Machining-induced residual stress: experimentation and modeling. J Manuf Sci Eng 122(1):633–647
Masoudi S, Amini S, Saeidi E, Eslami-Chalander H (2015) Effect of machining-induced residual stress on the distortion of thin-walled parts. Int J Adv Manuf Technol 76(1):597–608
Shao Y, Fergani O, Li B, Liang SY (2016) Residual stress modeling in minimum quantity lubrication grinding. Int J Adv Manuf Technol 83(5):743–751
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zeng, H., Yan, R., Peng, F. et al. An investigation of residual stresses in micro-end-milling considering sequential cuts effect. Int J Adv Manuf Technol 91, 3619–3634 (2017). https://doi.org/10.1007/s00170-017-0088-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0088-5