Machining induced residual stress in structural aluminum parts

Machining operations of aluminum structural parts are typically carried out under high feeds and high cutting speeds. Under these conditions, high thermo mechanical loads are exerted on the workpiece, which may result in changes in the subsurface material. Residual stresses can be one of the machining induced changes and can lead to considerable rejection rates caused by part distortion. Due to their significant economic importance, it is essential to understand the influence of the machining process on the residual stresses in aluminum. This paper presents the influence of the machining parameters as well as the cutting edge geometry on residual stress of work-pieces made out of a forged aluminum alloy.