Experimental analysis on compressive residual stress distribution induced by high speed face-milling processes

The residual stress distribution beneath workpiece surfaces machined by high speed milling process was investigated, tests of face milling were conducted in the frame of a factorial design and X-ray diffraction analysis of specimens was performed to obtain the residual stress distribution by electro-polishing method. The influences of cutting parameters on characteristics of the compressive stress distribution were studied according the regression predictive models fitting from residual stress distributions measured in tests. It is shown that high speed milling can induce a compressive stress distribution below the machined surface. A Cubic/Linear rational model and a third-degree polynomial model are effective for fitting of the compressive stress distribution. The level of compressive residual stresses depends on the cutting parameters used in tests and feed per tooth is the decisive factor on the residual stresses distribution.