Prediction the effect of milling parameters upon the residual stresses through using Taghuchi method

The important role in the performance of machined parts and structures is residual stresses, namely, in the following aspects corrosion resistance, fatigue life and part distortion. The aim of this research was to predict the residual stresses in aluminum alloy Al-6061 workpiece after machining; this prediction of residual stresses was applied with different value of cutting speed, feed rate and depth of cut using Taguchi method. The model is verified with experimental measurements of residual stresses. With the analytical model presented in this work, Feed rate is the most important variable that affect on maximum residual stress after that cutting depth and rotational speed substantial reduction in computational time is achieved in the predictions of residual stresses. The result of this research is the contribution of depth of cut, rotational speed and feed with respect to residual stress is (67.07, 24.8 and8.13) % respectively.