Influence of Process Parameters on Residual Stresses Induced by Milling of Aluminum Alloy Using Taguchi’s Techniques

In this paper, the straight flute end-milling cutter used for machining of Al-Si-Mg-Fe alloy work pieces was investigated. The machining processes could induce residual stresses that enhance greatly the performance of the machined component. Machining residual stresses correlate very closely with the cutting parameters. In the experiments, the residual stress on the surface of workpiece was measured by using holedrilling strain gauge method. This paper presents a study of the Taguchi design application for CNC end milling operations. The influence of high-speed end milling on residual stresses in Al-Si-Mg-Fe alloy work pieces, which were cast by the sand, investment and die casting method, was investigated. The magnitude and distributions of the residual stresses are closely correlated with cutting forces and temperature. The T6 heat treatment for Al-Si-Mg-Fe alloy offers a low average residual stress during the high-speed milling operation The results concluded that the residual stresses induced in the workpiece increases with increase in feed rate and increases with increase in depth of cut.