Investigation of residual impact stress and its effects on the precision during milling of the thin-walled part

  • Xiaohui Jiang
  • Yihong Zhu
  • Zhenya Zhang
  • Miaoxian Guo
  • Zishan Ding


Residual stress has a lasting effect on the deflection of machined thin-walled parts, which also strictly restricts the use of products. This paper finds that there exists residual impact stress during the high-speed cutting machining of thin-walled parts, which is very unfavorable to the quality of thin-walled parts. Obvious residual impact stress exists during the cutting-in and cutting-out stages, while stable machining residual stress exists in the middle stage. At the cutting-in and cutting-out positions of tool, the residual impact stress generated by a parameter combination of low speed, large feed, and large depth of cut is much smaller than that generated by other combinations of process parameters. The residual impact stress on multiple machined surfaces can propagate on the surface to form distribution with equal stress energy areas. By increasing the linear cutting speed, the surface and subsurface residual stress values can be decreased to some extent. Although the cutting efficiency improves, the deflection caused by residual stress reduces. Based on these results, experimental verification is carried out on the thin-walled parts. And the evidence shows the presented approach is useful to reduce the residual impact stresses; therefore, distortion of thin-walled part is also within control.


Thin-walled part Residual impact stress Cutting-in stage Cutting-out stage Deflection 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


Funding information

This paper is supported by National Natural Science Foundation of China (Grant No. 51505291).


  1. 1.
    Li JG, Wang SQ (2017) Distortion caused by residual stresses in machining aeronautical aluminum alloy parts—recent advances. Int J Adv Manuf Technol 89:997–1012CrossRefGoogle Scholar
  2. 2.
    Jiang XH, Li BZ, Wang LF, Wang ZH, Li HL (2016) An approach to evaluate the effect of cutting force and temperature on the residual stress generation during milling. Int J Adv Manuf Technol 87:2305–2317CrossRefGoogle Scholar
  3. 3.
    Wojciechowski S, Maruda RW, Krolczyk GM, Nieslony P (2018) Application of signal to noise ratio and grey relational analysis to minimize forces and vibrations during precise ball end milling. Precis Eng 51:582–596CrossRefGoogle Scholar
  4. 4.
    Wojciechowski S, Maruda RW, Barrans S, Nieslony P, Krolczyk GM (2017) Optimisation of machining parameters during ball end milling of hardened steel with various surface inclinations. Measurement 111:18–28CrossRefGoogle Scholar
  5. 5.
    Zeng HH, Yan R, Peng FY, Zhou L, Deng B (2017) An investigation of residual stresses in micro-end-milling considering sequential cuts effect. Int J Adv Manuf Technol 91(9–12):3619–3634CrossRefGoogle Scholar
  6. 6.
    Li BZ, Jiang XH, Yang JG, Liang SY (2015) Effects of depth of cut on the redistribution of residual stress and distortion during the milling of thin-walled part. J Mater Process Technol 216:223–233CrossRefGoogle Scholar
  7. 7.
    Huang K, Yang WY, Ye XM (2018) Adjustment of machining-induced residual stress based on parameter inversion. Int J Mech Sci 135:43–52CrossRefGoogle Scholar
  8. 8.
    James MN (2011) Residual stress influences on structural reliability. Eng Fail Anal 18:1909–1920CrossRefGoogle Scholar
  9. 9.
    de Camargo JAM, Cioffi MOH, Cornelis HJ, Costa MYP (2007) Coating residual stress effects on fatigue performance of 7050-T7451 aluminum alloy. Surf Coat Technol 201:9448–9455CrossRefGoogle Scholar
  10. 10.
    Nieslony P, Krolczyk GM, Wojciechowski S, Chudy R, Zak K (2018) Surface quality and topographic inspection of variable compliance part after precise turning. Appl Surf Sci 434:91–101CrossRefGoogle Scholar
  11. 11.
    Jiang XH, Zhang ZY, Ding ZS, Fergani O, Liang SY (2017) Tool overlap effect on redistributed residual stress and shape distortion produced by the machining of thin-walled aluminum parts. Int J Adv Manuf Technol 93(5–8):2227–2242CrossRefGoogle Scholar
  12. 12.
    Jiang XH, Wang YF, Ding ZS, Li HL (2017) An approach to predict the distortion of thin wall parts during milling affected by residual stress. Int J Adv Manuf Technol 93(9–12):4203–4216CrossRefGoogle Scholar
  13. 13.
    Tlusty J, Smith S, Winfough WR (1996) Techniques for the use of long slender end mills in high speed milling. Ann CIRP 45(1):393–396CrossRefGoogle Scholar
  14. 14.
    Li JL, Jing LL, Chen M (2009) An FEM study on residual stresses induced by high-speed end-milling of hardened steel SKD11. J Mater Process Technol 209:4515–4520CrossRefGoogle Scholar
  15. 15.
    Lazoglu I, Ulutan D, Alaca BE, Engin S (2008) An enhanced analytical model for residual stress prediction in machining. CIRP Ann Manuf Technol 57:81–84CrossRefGoogle Scholar
  16. 16.
    Lee HH, Gangwar KD, Park KT, Woo W, Kim HS (2017) Neutron diffraction and finite element analysis of the residual stress distribution of copper processed by equal-channel angular pressing. Mater Sci Eng 682:691–697CrossRefGoogle Scholar
  17. 17.
    Nose M, Amano H, Okada H, Yusa Y, Maekawa A, Kamaya M, Hiroshi K (2017) Computational crack propagation analysis with consideration of weld residual stresses. Eng Fract Mech 182:708–731CrossRefGoogle Scholar
  18. 18.
    Zong WJ, Li D, Cheng K, Sun T, Liang YC (2007) Finite element optimization of diamond tool geometry and cutting-process parameters based on surface residual stresses. Int J Adv Manuf Technol 32:666–674CrossRefGoogle Scholar
  19. 19.
    Liu WY, Kim JR, Rasmussen KT, Zhang H (2017) Modelling and probabilistic study of the residual stress of cold-formed hollow steel sections. Eng Struct 150:986–995CrossRefGoogle Scholar
  20. 20.
    Yu QM, He Q (2018) Effect of material properties on residual stress distribution in thermal barrier coatings. Ceram Int 44:3371–3380CrossRefGoogle Scholar
  21. 21.
    Ferro P, Berto F, James NM (2016) Asymptotic residual stress distribution induced by multipass welding processes. Int J Fatigue 101:421–429CrossRefGoogle Scholar
  22. 22.
    Agrawal S, Joshi SS (2013) Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel. J Manuf Process 15(1):167–179CrossRefGoogle Scholar
  23. 23.
    Liang SY, Su JC (2007) Residual stress modeling in orthogonal machining. CIRP Ann Manuf Technol 56(1):65–68MathSciNetCrossRefGoogle Scholar
  24. 24.
    Ghasri-Khouzani M, Peng H, Rogge R, Attardo R, Ostiguy P, Neidig J, Billo R, Hoelzle D, Shankar MR (2017) Experimental measurement of residual stress and distortion in additively manufactured stainless steel components with various dimensions. Mater Sci Eng A 707:689–700CrossRefGoogle Scholar
  25. 25.
    Shi XF, Hussain G, Butt SI, Song F, Huang DH, Liu Y (2017) The state of residual stresses in the Cu/Steel bonded laminates after ISF deformation: An experimental analysis. J Manuf Process 30:14–26CrossRefGoogle Scholar
  26. 26.
    Borja C, Virginia GN, Oscar G, Ana A, Carmen S (2012) Influences of measuring residual stresses in components. Mater Des 35:572–588CrossRefGoogle Scholar
  27. 27.
    Caruso S, Umbrello D, Outeiro JC, Filice L, Micari F (2011) An experimental investigation of residual stresses in hard machining of AISI 52100 steel. Procedia Eng 19:67–72CrossRefGoogle Scholar
  28. 28.
    Rossini NS, Dassisti M, Benyounis KY, Olabi AG (2012) Methods of measuring residual stresses in components. Mater Des 35:572–588CrossRefGoogle Scholar
  29. 29.
    Jacobus K, DeVor RE, Kapoor SG (2000) Machining-induced residual stress: experimentation and modeling. J Manuf Sci Eng 122(1):20–30CrossRefGoogle Scholar
  30. 30.
    Outeiroa JC, Umbrello D, Saoubi RM (2006) Experimental and numerical modelling of the residual stresses induced in orthogonal cutting of AISI 316L steel. Int J Mach Tools Manuf 46:1786–1794CrossRefGoogle Scholar
  31. 31.
    Kuang HF, Wu CF (1995) A residual stress model for the milling of aluminum alloy (2014-T6). J Mater Process Technol 51:87–105CrossRefGoogle Scholar
  32. 32.
    Mohammad MP, Razfar MR, Saffar RJ (2010) Numerical investigating the effect of machining parameters on residual stresses in orthogonal cutting. Simul Model Pract Theory 18:378–389CrossRefGoogle Scholar
  33. 33.
    Zhu PY, Liu DS, Peng YD (2001) Inverse approach to determine piston profile from impact stress waveform on given non-uniform rod. Trans Nonferrous Metals Soc China 11(2):297–300Google Scholar
  34. 34.
    Min KL, Kim WW, Chang KR (1999) Liquid impact erosion mechanism and theoretical impact stress analysis in TiN-coated steam turbine blade materials. Metall Mater Trans A 30(4):961–968CrossRefGoogle Scholar
  35. 35.
    Green WA, Green ER (1990) Impact stress waves in fibre composite laminates, Developments in the Science and Technology of Composite Materials. Springer, Netherlands, pp 993–998CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Xiaohui Jiang
    • 1
  • Yihong Zhu
    • 1
  • Zhenya Zhang
    • 1
  • Miaoxian Guo
    • 1
  • Zishan Ding
    • 1
  1. 1.College of Mechanical EngineeringUniversity of Shanghai for Science and TechnologyShanghaiPeople’s Republic of China

Personalised recommendations