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.
In this work, a recently developed method based on the change of distance between collinear indents is used to evaluate different states of residual stress, which were generated in samples of AA 6082-T6 and AA 7075-T6 aluminium alloys milled at high speed. One of the advantages of this method, which needs a universal measuring machine, is not requiring neither the use of specific equipment nor highly skilled operators. Also, by integrating an indentation device to the mentioned machine, the absolute error of measurement can be reduced. In results obtained in samples subjected to different cutting conditions it is observed a correlation between the stress values and the depth of cut, showing the AA 6082-T6 alloy higher susceptibility to be stressed. Furthermore, the high sensitivity of the method allowed detecting very small differences in the values reached by different normal components in the zones corresponding to climb and conventional cutting. It is important to note that these differences were similar for both evaluated alloys. Finally, the directions associated with the principal components of residual stress, where maximum local plastic stretching occurs, were found to be strongly dependent on the rolling direction prior to machining.
This work aims to propose a micro-indent method to evaluate the correlation between the relaxation of residual stresses and the shape changes of the polycrystalline lattice in specimens of a rolled plate of AA 6082-T6 aluminium alloy. Rolling strengthens the surface of the plate by introducing compressive residual stresses. Then, these stresses are relaxed by thermal distension. The method of micro-indents allowed measuring residual displacements with an error below ± 300 nm. The results obtained reveal that the rolling direction plays a vital role in terms of asymmetric expansion of the lattice. Furthermore, the lattice accumulates and restores elastic strain energy in the clockwise and anti-clockwise direction of rotation, alternatively. Finally, when the stress release process is finishing, the lattice adjusts the angle of rotation to approximate to the initial geometric shape.
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