Effect of cutting parameters on the residual stress distribution generated by pocket milling of 2219 aluminum alloy

This work describes the experimental investigation of the residual stress distribution in the square pocket milling of 2219 aluminum alloy. The results reveal that the axial depth of cut is the most important factor influencing the residual stress distribution of the machined pocket surface, and the more tensile stress states are found with the increase in axial cutting depth due to the thermal deformation. The dominant mechanical deformation at all spindle speeds tends to produce the compressive residual stress. Altered feed rate and radial depth of cut show little changes in the residual stress distributions and the average values. In addition, the pattern of residual stress distribution of the square pocket surface is dramatically changed and the more tensile stresses are produced as the milling operation further proceeds. From this investigation, it is suggested to shorten the cutting time by raising the cutting parameters such as the feed rate and the radial depth of cut to achieve the compressive stress and the good surface roughness.