Milling induced residual stresses in structural parts out of forged aluminium alloys.

Machining operations of aluminum structural parts are typically carried out under high feeds and high cutting speeds. These cutting conditions exert thermal and mechanical loads on the workpiece, which cause changes in the subsurface material. Residual stresses belong to the machining induced changes and can lead to considerable rejection rates as a consequence of part distortion. Due to the significant economic importance, it is essential to investigate the influence of the machining process on the residual stresses in aluminum. This paper presents the influence of cutting parameters and tool geometry on the level of residual stress in workpieces out of forged aluminum alloys.