In this work, a recently developed method based on the change of distance between collinear indents is used to evaluate different states of residual stress, which were generated in samples of AA 6082-T6 and AA 7075-T6 aluminium alloys milled at high speed. One of the advantages of this method, which needs a universal measuring machine, is not requiring neither the use of specific equipment nor highly skilled operators. Also, by integrating an indentation device to the mentioned machine, the absolute error of measurement can be reduced. In results obtained in samples subjected to different cutting conditions it is observed a correlation between the stress values and the depth of cut, showing the AA 6082-T6 alloy higher susceptibility to be stressed. Furthermore, the high sensitivity of the method allowed detecting very small differences in the values reached by different normal components in the zones corresponding to climb and conventional cutting. It is important to note that these differences were similar for both evaluated alloys. Finally, the directions associated with the principal components of residual stress, where maximum local plastic stretching occurs, were found to be strongly dependent on the rolling direction prior to machining.
Cite this paper
F. Díaz, C. Mammana and A. Guidobono, "Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method," Modern Mechanical Engineering, Vol. 2 No. 4, 2012, pp. 143-150. doi: 10.4236/mme.2012.24019.
 R. M’Saoubi, J. C. Outeiro, H. Chandrasekaran, O. W. Dillon Jr. and I. S. Jawahir, “A Review of Surface Integrity in Machining and Its Impact on Functional Performance and Life of Machined Products,” International Journal of Sustainable Manufacturing, Vol. 1, No. 1-2, 2008, pp. 203-236.
 A. M. Abr?o, J. L. Silva Ribeiro and J. Paulo Davim, “Surface Integrity,” In: J. P. Davim, Ed., Machining of Hard Materials, Springer-Verlag, London, 2011, pp. 115-141. doi:10.1007/978-1-84996-450-0_4
 F. V. Díaz, C. A. Mammana, A. P. M. Guidobono and R. E. Bolmaro, “Analysis of Residual Strain and Stress Distributions in High Speed Milled Specimens Using an Indentation Method,” International Journal of Engineering and Applied Sciences, Vol. 7, No. 1, 2011, pp. 40-46.
 P. J. Withers and H. K. Bhadeshia, “Residual Stress. Part 1—Measurement Techniques,” Materials Science and Technology, Vol. 17, No. 4, 2001, pp. 355-365.
 P. J. Hoffman, E. S. Hopewell, B. Janes and K. M. Sharp Jr., “Precision Machining Technology,” Delmar Cengage Learning, New York, 2011.
 E. Brinksmeier, “X-Ray Stress Measurement—A Tool for the Study and Layout of Machining Processes,” Annals of the CIRP, Vol. 33, No. 1, 1985, pp. 485-490.
 J. Hua, R. Shivpuri, X. Cheng, V. Bedekar, Y. Matsumoto, F. Hashimoto and T. R. Watkins, “Effect of Feed rate, Workpiece Hardness and Cutting Edge on Subsurface Residual Stress in the Hard Turning of Bearing Steel Using Chamfer + Hone Cutting Edge Geometry,” Materials Science and Engineering A, Vol. 394, No. 1-2, 2005, pp. 238-248. doi:10.1016/j.msea.2004.11.011
 A. L. Mantle and D. K. Aspinwall, “Surface Integrity of a High Speed Milled Gamma Titanium Aluminide,” Journal of Materials Processing Technology, Vol. 118, No. 1-3, 2001, pp. 143-150.
 B. R. Sridhar, G. Devananda, K. Ramachandra and R. Bhat, “Effect of Machining Parameters and Heat Treatment on the Residual Stress Distribution in Titanium Alloy IMI-834,” Journal of Materials Processing Technology, Vol. 139, 2003, pp. 628-634.
 A. W. Warren, Y. B. Guo and M. Weaver, “The Influence of Machining Induced Residual Stress and Phase Transformation on the Measurement of Subsurface Mechanical Behaviour Using Nanoindentation,” Surface and Coatings Technology, Vol. 200, No. 11, 2005, pp. 3459-3467.
 J. E. Wyatt and J. T. Berry, “A New Technique for the Determination of Superficial Residual Stresses Associated with Machining and Other Manufacturing Processes,” Journal of Materials Processing Technology, Vol. 171, No. 1, 2006, pp. 132-140.
 K. H. Fuh and C. Wu, “A Residual Stress Model for the Milling of Aluminium Alloy (2014-T6),” Journal of Materials Processing Technology, Vol. 51, No. 1-4, 1995, pp. 87-105. doi:10.1016/0924-0136(94)01355-5
 B. Rao and Y. C. Shin, “Analysis on High-Speed Face-Milling of 7075-T6 Aluminum Using Carbide and Diamond Cutters,” International Journal of Machine Tools and Manufacture, Vol. 41, No. 12, 2001, pp. 1763-1781.
 B. Denkena and L. De Leon, “Milling Induced Residual Stresses in Structural Parts out of Forged Aluminium Alloys,” International Journal of Machining and Machinability of Materials, Vol. 4, No. 4, 2008, pp. 335-344.
 F. V. Díaz, R. E. Bolmaro, A. P. M. Guidobono and E. F. Girini, “Determination of Residual Stresses in High Speed Milled Aluminium Alloys Using a Method of Indent Pairs,” Experimental Mechanics, Vol. 50, No. 2, 2010, pp. 205-215. doi:10.1007/s11340-009-9288-8
 F. V. Díaz and C. A. Mammana, “Study of Residual Stresses in Conventional and High-Speed Milling,” In: L. A. Filipovic, Ed., Milling: Operations, Applications and Industrial Effects, Nova Science Publishers, Inc., New York, 2012, pp. 127-155.
 C. A. Mammana, F. V. Díaz, A. P. M. Guidobono and R. E. Bolmaro, “Study of Residual Stress Tensors in High-Speed Milled Specimens of Aluminium Alloys Using a Method of Indent Pairs,” Research Journal of Applied Sciences, Engineering and Technology, Vol. 2, No. 8, 2010, pp. 749-756.
 B. Chamberlain, “Maquinability of Aluminum Alloys,” In: Metals Handbook—Properties and Selection: Nonferrous Alloys and Pure Metals, 9th Ed., ASM International Handbook Committee, New York, 1979, Vol. 2, pp 187-190.
 J. M. Gere, “Mechanics of Materials,” Brooks/Cole, Pacific Grove, 2001.
 P. R. Bevington and D. K. Robinson, “Data Reduction and Error Analysis for the Physical Sciences,” McGraw-Hill, New York, 2002.