Analysis and X-ray Measurements of Cutting Residual Stresses in 7075 Aluminum Alloy in High Speed Machining

Cutting residual stresses (stresses that result after cutting a material) of a machined layer has a direct relationship with machined surface quality. The condition of a machined surface is affected by several factors, including tool and workpiece materials, cutting parameters (cutting speed, feed rate, and depth of cut), and contact conditions at the tool/workpiece interface. This paper presents the effects of machined surface quality and cutting parameters on residual stress distribution. The cutting residual stress of 7075 aluminum alloy is experimentally and numerically investigated by an X-ray diffaction technique and an elastic-viscoplastic FEM formulation. The results show that cutting residual stresses increase with machined surface roughness. Among other cutting conditions, main spindle rotational speed, feed speed, and tool condition have a strong influence on surface residual stresses.