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 thermomechanical loads are exerted on the workpiece, which may lead to changes in the subsurface material. Residual stresses belong to the machining induced changes and can lead to considerable rejection rates due to 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 workpieces made out of a wrought aluminum alloy.