How are residual stresses influenced by endmilling parameters? This research delves into the residual stresses induced by endmilling of annealed AISI 4340 steel. The experiments examined the effects of location, axial depth of cut, and feed on the machining-induced residual stresses within the cut geometry. The study demonstrated that each of the location, feed, and axial depth of cut factors exerted a considerable influence on the machining-induced residual stresses. Through experimentation, it was revealed that by expressing the residual stresses in a coordinate frame fixed in the tool, simplification could be achieved. The experiment reveals that the stresses at multiple locations within the cut geometry exhibited strong similarities when expressed using this framework. The outcome indicates that the location, feed, and axial depth of cut strongly affect residual stresses from end-milling. In a coordinate frame fixed in the tool the effects are lessened, thus indicating a simplification of the residual stress results. This work provides valuable insights for optimizing endmilling processes to control residual stresses and improve the performance of machined components.
Published in the Journal of Manufacturing Science and Engineering, this research aligns perfectly with the journal's focus on manufacturing processes and material behavior. By investigating the residual stresses generated by endmilling, the paper addresses a key aspect of manufacturing engineering relevant to the journal's readership. The work contributes to the understanding of how machining parameters influence the properties of manufactured components.