Formation of Compressive Residual Stress by Face Milling Steel AISI 1045

Abstract Machining residual stresses correlate very closely with the cutting parameters and the tool geometries. This research work aims to investigate the effect of cutting speed, feed rate and depth of cut on the surface residual stress of steel AISI 1045 after face milling operation. Aft...

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Autores principales:	Ahmed Naif Al-Khazraji, Samir Ali Al-Rabii, Samir Zidan Al-Fahadawy
Formato:	article
Lenguaje:	EN
Publicado:	Al-Khwarizmi College of Engineering – University of Baghdad 2017
Materias:	Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization. Chemical engineering TP155-156 Engineering (General). Civil engineering (General) TA1-2040
Acceso en línea:	https://doaj.org/article/4939b04570614834a070e3eaa4c71775
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spelling	oai:doaj.org-article:4939b04570614834a070e3eaa4c717752021-12-02T05:46:59ZFormation of Compressive Residual Stress by Face Milling Steel AISI 10451818-11712312-0789https://doaj.org/article/4939b04570614834a070e3eaa4c717752017-12-01T00:00:00Zhttp://alkej.uobaghdad.edu.iq/index.php/alkej/article/view/213https://doaj.org/toc/1818-1171https://doaj.org/toc/2312-0789 Abstract Machining residual stresses correlate very closely with the cutting parameters and the tool geometries. This research work aims to investigate the effect of cutting speed, feed rate and depth of cut on the surface residual stress of steel AISI 1045 after face milling operation. After each milling test, the residual stress on the surface of the workpiece was measured by using X-ray diffraction technique. Design of Experiment (DOE) software was employed using the response surface methodology (RSM) technique with a central composite rotatable design to build a mathematical model to determine the relationship between the input variables and the response. The results showed that both the feed rate and the cutting speed are the significant factors controlling the surface residual stress, while the depth of cut had no influence. A quadratic empirical model was developed with a 95% confidence level, and a good agreement was found between the experimental and predicted results. A numerical optimization was then conducted through DOE program to find the optimum surface residual stress at the optimum cutting parameters, depending on the maximum desirability obtained. The optimum compressive surface residual stress (-224.361 MPa) was found at cutting speed of 69.2 m/min, feed rate of 0.4 m/min and depth of cut of 0.4 mm. Keywords: Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization. Ahmed Naif Al-KhazrajiSamir Ali Al-RabiiSamir Zidan Al-FahadawyAl-Khwarizmi College of Engineering – University of BaghdadarticleFace milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization.Chemical engineeringTP155-156Engineering (General). Civil engineering (General)TA1-2040ENAl-Khawarizmi Engineering Journal, Vol 11, Iss 1 (2017)
institution	DOAJ
collection	DOAJ
language	EN
topic	Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization. Chemical engineering TP155-156 Engineering (General). Civil engineering (General) TA1-2040
spellingShingle	Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization. Chemical engineering TP155-156 Engineering (General). Civil engineering (General) TA1-2040 Ahmed Naif Al-Khazraji Samir Ali Al-Rabii Samir Zidan Al-Fahadawy Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
description	Abstract Machining residual stresses correlate very closely with the cutting parameters and the tool geometries. This research work aims to investigate the effect of cutting speed, feed rate and depth of cut on the surface residual stress of steel AISI 1045 after face milling operation. After each milling test, the residual stress on the surface of the workpiece was measured by using X-ray diffraction technique. Design of Experiment (DOE) software was employed using the response surface methodology (RSM) technique with a central composite rotatable design to build a mathematical model to determine the relationship between the input variables and the response. The results showed that both the feed rate and the cutting speed are the significant factors controlling the surface residual stress, while the depth of cut had no influence. A quadratic empirical model was developed with a 95% confidence level, and a good agreement was found between the experimental and predicted results. A numerical optimization was then conducted through DOE program to find the optimum surface residual stress at the optimum cutting parameters, depending on the maximum desirability obtained. The optimum compressive surface residual stress (-224.361 MPa) was found at cutting speed of 69.2 m/min, feed rate of 0.4 m/min and depth of cut of 0.4 mm. Keywords: Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization.
format	article
author	Ahmed Naif Al-Khazraji Samir Ali Al-Rabii Samir Zidan Al-Fahadawy
author_facet	Ahmed Naif Al-Khazraji Samir Ali Al-Rabii Samir Zidan Al-Fahadawy
author_sort	Ahmed Naif Al-Khazraji
title	Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
title_short	Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
title_full	Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
title_fullStr	Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
title_full_unstemmed	Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
title_sort	formation of compressive residual stress by face milling steel aisi 1045
publisher	Al-Khwarizmi College of Engineering – University of Baghdad
publishDate	2017
url	https://doaj.org/article/4939b04570614834a070e3eaa4c71775
work_keys_str_mv	AT ahmednaifalkhazraji formationofcompressiveresidualstressbyfacemillingsteelaisi1045 AT samiralialrabii formationofcompressiveresidualstressbyfacemillingsteelaisi1045 AT samirzidanalfahadawy formationofcompressiveresidualstressbyfacemillingsteelaisi1045
_version_	1718400226048344064

Formation of Compressive Residual Stress by Face Milling Steel AISI 1045

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