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

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 st...

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Bibliographic Details
Published in:Materials 2024-03, Vol.17 (5), p.1193
Main Authors: Zawada-Michałowska, Magdalena, Pieśko, Paweł, Mrówka-Nowotnik, Grażyna, Nowotnik, Andrzej, Legutko, Stanisław
Format: Article
Language:English
Subjects:
Aircraft
Alloys
Aluminum base alloys
Corrosion
Cutting force
Cutting parameters
Cutting speed
Genetic algorithms
Geometry
High speed machining
Load
Machining
Milling (machining)
Neural networks
Operational problems
Optimization
Phase transitions
Plates (structural members)
Residual stress
Strain
Surface layers
Tensile stress
Thin walls
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Summary: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 = 750 m/min. At a cutting speed = 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.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma17051193