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© 2025 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). Notwithstanding the ProQuest Terms and Conditions, you may use this content in accordance with the terms of the License.

Abstract

In this study, the correlations between milling conditions—namely, the cutting tool feed direction relative to the rolling direction, the milling type, the coolant application, as well as the cutting speed—and the surface residual stress of a selected aluminum alloy (2024 T351) were investigated. Determining the type and magnitude of residual stress is of paramount importance as this stress is among the primary causes of post-machining strain of thin-walled components. On the basis of the experimental results, it was found that all factors analyzed significantly affect the residual stress state. Specifically, milling in the parallel direction induces lower residual tensile stress compared to milling in the perpendicular direction. Analogously, up-milling yields lower tensile residual stress than down-milling, and flood cooling leads to lower tensile residual stress than MQL. It was clearly confirmed that as cutting speed increases, tensile residual stress also increases, but only up to a certain threshold; once the high-speed cutting regime is reached, tensile residual stress begins to decrease. Consequently, the proper selection of milling parameters is a crucial consideration for optimizing machining processes and minimizing machining-induced residual stress.

Details

Title
Experimental Investigation of the Influence of Milling Conditions on Residual Stress in the Surface Layer of an Aerospace Aluminum Alloy
Author
Zawada-Michałowska, Magdalena  VIAFID ORCID Logo  ; Anasiewicz, Kamil  VIAFID ORCID Logo  ; Korpysa, Jarosław  VIAFID ORCID Logo  ; Pieśko, Paweł  VIAFID ORCID Logo 
First page
811
Publication year
2025
Publication date
2025
Publisher
MDPI AG
e-ISSN
19961944
Source type
Scholarly Journal
Language of publication
English
ProQuest document ID
3171127572
Copyright
© 2025 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). Notwithstanding the ProQuest Terms and Conditions, you may use this content in accordance with the terms of the License.