Evaluation of Residual Stresses Induced by Face Milling Using a Method of Micro-indents

The aim of this study is to determine and evaluate residual stresses induced by face milling in different zones, which are associated with asymmetries in orientation of cutting edge. In this study, a micro-indent method is used to determine these stresses, which were induced in samples of AA 7075-T6 aluminum alloy. The residual displacements were measured, with high accuracy, using a universal measuring machine. This study includes a thorough data analysis using Mohr's circles, which enabled to assess the stress states in all in-plane directions. The results obtained in samples subjected to different combinations of process parameters showed the introduction of compressive normal components for all directions of each zone evaluated. From the high sensitivity of the microindent method used, it was possible to detect smaller differences generated between the levels reaching the stress components in the cutting zones evaluated. Furthermore, these differences were similar for all evaluated directions when the highest feed rate was selected. This significant fact, finally, would reveal equivalent differences between asymmetrical zones, regarding the combination of local plastic deformation and heat reaching the milled surface, for all in-plane directions.