Modelling the effect of feed rate on residual stresses induced due to milling using experimental and numerical methods

Abstract

The surface integrity of any manufactured product produced in machining process has proved to have a significant impact on the performance of the product. Many parameters influence the integrity of the surface, few of which are microstructure of the material, surface roughness, residual stresses etc. Out of which the present work focuses on the residual stress of the machining, which majorly effects the fatigue strength of the product. Understanding the significance of residual stresses in machining, and influencing it using three basic parameters: feed, cutting speed and depth of cut to increase the products performance and life by optimizing these measures to best possible combination. It is done using both experimental and numerical methods and authors have compared the numerical and experimental values. For experimental purposes AISI 1045 steel was used and the residual stresses measurement was done using X-ray diffraction method.