Experimentation on the Residual Stresses Generated by Endmilling

Residual stress measurements from endmilling of annealed AISI 4340 have been made at multiple points within the cut geometry to investigate the effects of location on the machining-induced residual stresses from endmilling. In the same experiments the effects of axial depth of cut and feed on the residual stresses induced in the machined surface have been investigated in a design of experiments framework. The experimentation demonstrates that location, feed and axial depth of cut have strong influences on the machining-induced residual stresses from end-milling when expressed in a workpiece coordinate frame. In addition, expression of the residual stresses in a coordinate frame fixed in the tool demonstrates a simplification in the residual stresses from endmilling in that the stresses at multiple locations within the cut geometry show strong similarities when expressed in this coordinate frame.