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Determination of Residual Stresses in High Speed Milled Aluminium Alloys Using a Method of Indent Pairs

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Abstract

An improved method of indent pairs is utilised to determine residual stresses in high speed milling specimens of AA 6082-T6 and AA 7075-T6 aluminium alloys. To carry out the measurement procedure, this approach does not need specific equipment but only requires a universal measuring machine and an oven. An indentation device is incorporated to the measuring machine, which allows reducing the absolute error of measurement to just ±0.9 MPa. The geometry of the tool and cutting parameters are selected to evaluate the sensitivity of the method. The residual stress distributions generated by high speed milling are exhaustively evaluated taking into account orthogonal components of cutting speed and tangential force, which are parallel and perpendicular to feed direction.

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Abbreviations

A:

elongation (%)

d :

depth of cut (mm)

E :

longitudinal elastic modulus (GPa)

f :

feed rate (mm/rev)

\( {F_{t_x}} \) :

tangential force component at the x direction (N)

\( {F_{t_y}} \) :

tangential force component at the y direction (N)

HV0.5:

Vickers micro-hardness (test load: 500 gf)

k 1 , k 2 :

elastic constants

K :

thermal conductivity (w/( m·K ))

R t :

non-dimensional thermal number

S :

specific heat capacity (J/( kg·K ))

u :

displacement component at the x direction (μm)

v :

displacement component at the y direction (μm)

V :

cutting speed (m/min)

V x :

cutting speed component at the x direction (m/min)

V y :

cutting speed component at the y direction (m/min)

X b , X a :

distances between indents located at the x direction, before and after the stress-relieving, respectively (mm)

Y b , Y a :

distances between indents located at the y direction, before and after the stress-relieving, respectively (mm)

α :

clearance angle (deg)

β :

fraction of energy from primary cutting zone to specimen surface

γ :

rake angle (deg)

ε x :

deformation component at the x direction

ε y :

deformation component at the y direction

υ :

Poisson’s ratio

ρ :

density (kg/m³)

σ x :

residual stress component at the x direction (MPa)

σ y :

residual stress component at the y direction (MPa)

σ u :

ultimate tensile strength (UTS) (MPa)

\( {\sigma_{{y_{0.2}}}} \) :

yield strength (MPa)

φ :

shear angle (deg)

χ :

entrance angle (deg)

Δu :

absolute error inherent to the u component (μm)

Δv :

absolute error inherent to the v component (μm)

ΔX b ,ΔX a :

absolute errors inherent to the distances X b and X a , respectively

ΔY b ,ΔY a :

absolute errors inherent to the distances Y b and Y a , respectively

Δε x :

absolute error inherent to the ε x component

Δε y :

absolute error inherent to the ε y component

Δσ x :

absolute error inherent to the σ x component (MPa)

Δσ y :

absolute error inherent to the σ y component (MPa)

\( \Delta \sigma_x^d \) :

variation in the σ x component due to an increase in the d parameter (MPa)

\( \Delta \sigma_y^d \) :

variation in the σ y component due to an increase in the d parameter (MPa)

\( \Delta \sigma_y^f \) :

variation in the σ y component due to an increase in the f parameter (MPa)

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Acknowledgments

The authors wish to express their sincere thanks to Eduardo Cravero and Silvio Acosta for their assistance during HSM test phase. This work was supported by the Departamento de Ingeniería Electromecánica and the Departamento de Ingeniería Industrial, Facultad Regional Rafaela, Universidad Tecnológica Nacional.

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Authors and Affiliations

  1. Departamento de Ingeniería Electromecánica—Departamento de Ingeniería Industrial, Facultad Regional Rafaela, Universidad Tecnológica Nacional, Bvd Roca 989, 2300, Rafaela, Argentina

    F. V. Díaz

  2. Instituto de Física Rosario (CONICET—UNR), Bvd 27 de Febrero 210 bis, 2000, Rosario, Argentina

    R. E. Bolmaro

  3. División Metrología Dimensional, Centro Regional Rosario (INTI), 2000, Rosario, Argentina

    A. P. M. Guidobono & E. F. Girini

Authors
  1. F. V. Díaz
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  2. R. E. Bolmaro
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  3. A. P. M. Guidobono
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  4. E. F. Girini
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Correspondence to F. V. Díaz.

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Díaz, F.V., Bolmaro, R.E., Guidobono, A.P.M. et al. Determination of Residual Stresses in High Speed Milled Aluminium Alloys Using a Method of Indent Pairs. Exp Mech 50, 205–215 (2010). https://doi.org/10.1007/s11340-009-9288-8

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  • DOI: https://doi.org/10.1007/s11340-009-9288-8

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