High-Speed Milling Characteristics and the Residual Stresses Control Methods Analysis of Thin-Walled Parts

Abstract

With FEM software of AdvantEdge, a model was created to analyze cutting force and thermal in the high-speed milling process, this model included a complete milling process of cutter radius. Combined with experiments validation, in high-speed milling, the normal force is greater than the tangential force and result in greater residual stress of that direction, which indicates that mechanical force play an essential part on the formation of residual stress. When the speed is over certain scope, the cutting force decreases, but the cutting temperature has been rising. In Roughing, by limiting the range of high-speed the residual tensile stress impact can be reduced. While in finishing, as the feed rate reducing the residual tensile stress will decrease greatly, improving the surface quality of thin-walled parts.

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

“…Arunachalam et al [6] recommended the use of low cutting speed (150 m/min) and small cutting depth (0.05 mm), which could help obtain compressive residual stress or minimum tensile residual stress. Li et al [7] believed that a smaller residual tensile stress would be generated at a higher feed speed. Garcia Navas et al [8] pointed out that the tensile residual stress of AISI 4340 steel can be reduced under the condition of smaller feed and higher cutting speed.…”

Detecting Milling Deformation in 7075 Aluminum Alloy Aeronautical Monolithic Components Using the Quasi-Symmetric Machining Method

“…Toribio et al [30] dealt with the effect of several residual stress profiles on the fatigue crack propagation in pre-stressing steel wires subjected to tension loading or bending moments. Considering the cutter radius of the milling process, Li et al [31] created a model to analyze cutting force and thermal properties in the high-speed milling process and, combined with experimental validation, indicate that mechanical forces play an essential part on the formation of residual stress. Palkowski et al [32] presented a 3-D model to calculate the residual stress state of drawn tubes in cold drawing processing.…”