The influence of milling induced residual stress on fatigue life of aluminum alloys

Berry, Luke J.; Wheatley, Greg; Ma, Wenchen; Nejad, Reza Masoudi; Berto, Filippo

doi:10.1016/j.finmec.2022.100096

Cited by 24 publications

(5 citation statements)

References 29 publications

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“…The main causes identified for these effects were the bending moment prompted by dynamic unbalance and tool vibration, which induce premature fatigue. A similar study presented by Berry et al [32] demonstrated that an increase in feed per tooth in combination with a reduction in cutting speed induces an increase in the compressive residual stress on the surface of the material, which improves the fatigue life of the machined components, although the tools deteriorate more easily. On the other hand, they stated that increasing the cutting speed reduces the residual stresses installed on the surface, while an increase in the feed per tooth induces a higher level of residual stresses.…”

Section: Milling Aa750 Aluminum Alloymentioning

confidence: 62%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

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Strategies for obtaining deep slots in soft materials can vary significantly. Conventionally, the tool travels along the slot, removing material mainly with the side cutting edges. However, a “plunge milling” strategy is also possible, performing the cut vertically, taking advantage of the tip cutting edges that almost reach the center of the tool. Although both strategies are already commonly used, there is a clear gap in the literature in studies that compare tool wear, surface roughness, and productivity in each case. This paper describes an experimental study comparing the milling of deep slots in AA7050-T7451 aluminum alloy, coated with a novel DLCSiO500W3.5O2 layer to minimize the aluminum adhesion to the tool, using conventional and plunge milling strategies. The main novelty of this paper is to present a broad study regarding different factors involved in machining operations and comparing two distinct strategies using a novel tool coating in the milling of aeronautical aluminum alloy. Tool wear is correlated with the vibrations of the tools in each situation, the cycle time is compared between the cases studied, and the surface roughness of the machined surfaces is analyzed. This study concludes that the cycle time of plunge milling can be about 20% less than that of conventional milling procedures, favoring economic sustainability and modifying the wear observed on the tools. Plunge milling can increase productivity, does not increase tool tip wear, and avoids damaging the side edges of the tool, which can eventually be used for final finishing operations. Therefore, it can be said that the plunge milling strategy improves economic and environmental sustainability as it uses all the cutting edges of the tools in a more balanced way, with less global wear.

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Section: Milling Aa750 Aluminum Alloymentioning

confidence: 62%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

View full text Add to dashboard Cite

show abstract

“…Nevertheless, the results confirmed that the cutting speed had a significant impact on the generated residual stress. Berry et al [ 47 ] confirmed that an increased feed per tooth in combination with a reduced cutting speed resulted in higher compressive stress on the surface of the material. The fatigue test results unanimously showed that higher compressive stress led to improved fatigue life, yet this could induce fracture at the interface between the deformed and undeformed zones in the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Zawada-Michałowska,

Pieśko,

Mrówka-Nowotnik

et al. 2024

Materials

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The production of thin-walled elements, especially those with large overall dimensions, poses numerous technological and operational problems. One of these problems relates to the machining-induced strain of such elements resulting from residual stress generated during the machining process. This study investigates the effect of the technological parameters of milling on residual stress in the surface layer of thin-walled plates made of aluminum alloy EN AW-2024 T351 for aerospace applications. The results have shown that residual stress increases with the cutting speed only to a certain point, reaching the maximum value at vc = 750 m/min. At a cutting speed vc = 900 m/min, residual stress significantly decreases, which probably results from the fact that the milling process has entered the High-Speed Cutting range, and this inference agrees with the results obtained for the cutting force component. Residual stress increases with the feed per tooth, while the relationship between residual stress and milling width is the same as that established for residual stress and variable cutting speed. Positive tensile stress is obtained in every tested case of the milling process. The results have also shown that the induced residual stress affects the strain of machined thin-walled parts, as proved by the strain results obtained for milled thin walls.

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“…Fretting crack nucleation mainly occurs in the surface or subsurface, which means fatigue cracks are sensitive to surface integrity. Berry et al 22 investigated the effect of milling‐induced residual stresses on crack behavior, and the results showed that the compressive residual stresses increased the fatigue life of the specimens. Nie et al 23 and Wang et al 24 investigated the effect of laser shock strengthening on the fatigue life of titanium alloys and showed that the compressive residual stress significantly increased the fatigue life of titanium alloys.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

Song

Pei

et al. 2023

Fatigue Fract Eng Mat Struct

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Conformal contact is a commonly presented contact form in assemblies. Nonproportional loading is the main characteristics of conformal contact, which leads to prominent difficulty in revealing fretting crack behavior. In this paper, a finite element prediction model for Ti-6Al-4V pin-hole contact fretting fatigue crack initiation was developed, which simultaneously considered the effect of fretting wear, surface roughness, surface skewness, surface kurtosis, and residual stress. The results show that phase differences of stress component, change in direction of principal stress, and high stress gradient are the main reasons for the initiation of fretting fatigue under conformal contact condition. The model based on the Fatemi-Socie (FS) parameter successfully predicted the location, orientation, and fatigue life of crack initiation, which agrees well with the experimental results. Additionally, machining-induced residual stress can effectively inhibit mode I crack initiation at valleys. Moreover, ignoring the surface microgeometry characteristics reduces the prediction accuracy of the crack behavior.

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The influence of milling induced residual stress on fatigue life of aluminum alloys

Cited by 24 publications

References 29 publications

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

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