A Review on Measurement Methods for Machining Induced Residual Stress
DOI:
https://doi.org/10.35806/ijoced.v1i2.64Keywords:
machining, residual stress, plastic deformation, microstructural change, residual stress measurementAbstract
The chip formation in mechanical machining / cutting process involves thermal loading and mechanical loading in the form of large plastic deformations, high strain, strain rates and high temperatures in the cutting zone. These loadings usually induce plastic deformation in the form of residual stresses in the surface and sub-surface of the machined workpiece. Residual stress issue is essential to be studied in order to control the quality and fatigue life of a component or part produced by machining process. Therefore, the magnitude and depth of the residual stresses into the workpiece sub-surface is important and necessary to be measured. The objective of this paper is to discuss various study on the effects of machining parameters on residual stress and residual stress measurement methods for machined workpiece namely non-destructive, semi-destructive and destructive methods. In addition, the effect of machining process into the metallurgical conditions of the workpiece in the form of microstructural changes is also discussed.
References
Andonian, A. T. and Danyluk, S. (1985) Residual stresses of thin, short rectangular plates, Journal of Materials Science, 20(12), pp. 4459–4464.
Bifano, T. G. and Hosler, J. B. (1993) Precision grinding of ultra-thin quartz wafers, Transactions of the ASME. Journal of Engineering for Industry. USA, 115(3), pp. 258–262.
Brinksmeier, E. and Tönshoff, H. K. (1985) X-ray stress measurement -- a tool for the study and layout of machining processes, CIRP Annals - Manufacturing Technology, 34(1), pp. 485–490.
Campbell, C. E., Bendersky, L. A., Boettinger, W. J. and Ivester, R. (2006) Microstructural characterization of Al-7075-T651 chips and work pieces produced by high-speed machining, Materials Science and Engineering: A, 430(1–2), pp. 15–26.
Cullity, B. D. and Stock, S. R. (2001) Elements of X-ray Diffraction. 3rd edn. Upper Saddle River, New Jersey: Prentice Hall.
Dive, V., Lasurkar, S., Limaje, K. and Yash, K. (2017) Study Paper on Methods of Measurement of Residual Stress in Mechanical Components, International Journal for Research in Applied Science and Engineering Technology (IJRASET), 5(IV).
Fang, G. and Zeng, P. (2005) Three-dimensional thermo-elastic-plastic coupled FEM simulations for metal oblique cutting processes, Journal of Materials Processing Technology, 168(1), pp. 42–48.
Guo, Y. B., Ammula, S. C. and Barkey, M. E. (2006) A wet etching method coupled with finite element analysis-based compliance function to determine residual stress in high-speed milling, Transactions of the ASME. Journal of Manufacturing Science and Engineering. USA: ASME, 128(3), pp. 792–801.
Hanna, C. R. (2007) Engineering Residual Stress into the Workpiece through the Design of Machining Process Parameters. Georgia Institute of Technology.
He, Z.-H., Zhang, X.-M. and Ding, H. (2016) Comparison of Residual Stresses in Cryogenic and Dry Machining of Inconel 718, Procedia CIRP, 46, pp. 19–22.
Huang, X., Sun, J., Li, J., Han, X. and Xiong, Q. (2013) An Experimental Investigation of Residual Stresses in High-Speed End Milling 7050-T7451 Aluminum Alloy, Advances in Mechanical Engineering. SAGE Publications, 5, p. 592659.
Jacobus, K., DeVor, R. E. and Kapoor, S. G. (2000) Machining-induced residual stress: experimentation & modelling, Journal of Manufacturing Science and Engineering, Transactions of the ASME, 122, pp. 20–31.
Kuczmaszewski, J., Łogin, W., Pieśko, P. and Zagórski, I. (2018) State of Residual Stresses After the Process of Milling Selected Aluminium Alloys, Advances in Science and Technology Research Journal, 12(1), pp. 63–73.
Kudryavtsev, Y. F. (2008) Residual Stress BT - Springer Handbook of Experimental Solid Mechanics, in Sharpe, W. N. (ed.). Boston, MA: Springer US, pp. 371–388.
Lu, L., Hu, S., Liu, L. and Yin, Z. (2016) High speed cutting of AZ31 magnesium alloy, Journal of Magnesium and Alloys, 4(2), pp. 128–134.
Ma, Y., Feng, P., Zhang, J.,Wu, Z. and Yu, D. (2016) Prediction of surface residual stress after end milling based on cutting force and temperature, Journal of Materials Processing Technology, 235, pp. 41–48.
Ma, Y., Yu, D. W. and Feng, P. F. (2014) FEM Analysis of Residual Stress Distribution and Cutting Forces in Orthogonal Cutting with Different Initial Stresses, Materials Science Forum. Trans Tech Publications Ltd, 800–801, pp. 380–384.
Masmiati, N. and Sarhan, A. A. D. (2015) Optimizing cutting parameters in inclined end milling for minimum surface residual stress – Taguchi approach, Measurement, 60, pp. 267–275.
Mehmet E. Kartal (2013) Analytical solutions for determining residual stresses in two-dimensional domains using the contour method, Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences. Royal Society, 469(2159), p. 20130367.
Nurprasetio, I. P., Budiman, B. A., and Triawan, F. (2017) Failure investigation of plastic shredding machine’s flange coupling based on mechanical analysis. Indonesian Journal of Science and Technology, 2(2), 124-133.
Perez, I., Madariaga, A., Cuesta, M., Garay, A., Arrazola, P. J., Ruiz, J. J., Rubio, F. J. and Sanchez, R. (2018) Effect of cutting speed on the surface integrity of face milled 7050-T7451 aluminium workpieces, Procedia CIRP, 71, pp. 460–465.
Prevey, P. S. (1986) X-ray diffraction residual stress techniques, in Metals Handbook. American Society for Metals, pp. 380–392.
Ramesh, K., Huang, H., Yin, L. and Yui, A. (2004) Surface waviness controlled grinding of thin mold inserts using chilled air as coolant, Materials and Manufacturing Processes. USA: Marcel Dekker, 19(2), pp. 341–354.
Rathbun, J. F. O. and Coffin, J. L. F. (1966) Experimental investigation of residual stress in quenched flat plates, Experimental Mechanics, 6(10), pp. 519–527.
Reimer, A. and Luo, X. (2018) Prediction of residual stress in precision milling of AISI H13 steel, Procedia CIRP, 71, pp. 329–334.
Robinson, J., Tanner, D., Truman, C. and Wimpory, R. (2011) Measurement and prediction of machining induced redistribution of residual stress in the aluminium alloy 7449, Experimental Mechanics. Springer Boston, 51(6), pp. 981–993.
Ruud, C. O. (1986) Residual stress measurements, in ASM handbook / prepared under the direction of the ASM International Handbook Committee. Materials Park, OH : ASM International, 1986-.
Saldana, C., Swaminathan, S., Brown, T. L., Moscoso, W., Mann, J. B., Compton, W. D. and Chandrasekar, S. (2010) Unusual applications of machining: controlled nanostructuring of materials and surfaces, Journal of Manufacturing Science and Engineering. ASME, 132(3), pp. 30908–30912.
Šarga, P. and Menda, F. (2013) Comparison of Ring-Core Method and Hole-drilling Method Used for Determining Residual Stresses, American Journal of Mechanical Engineering. Science and Education Publishing, 1(7), pp. 335–338.
Schajer, G. (2010) Relaxation methods for measuring residual stresses: techniques and opportunities, Experimental Mechanics. Springer Boston, 50(8), pp. 1117–1127.
Sharman, A. R. C., Hughes, J. I. and Ridgway, K. (2006) An analysis of the residual stresses generated in Inconel 718 when turning, Journal of Materials Processing Technology. Switzerland: Elsevier, 173(3), pp. 359–367.
Shaw, M. C. (1984) Metal cutting principles, Oxford Series on Advanced Manufacturing. Edited by 3. Oxford: Oxford University Press.
Shet, C. and Deng, X. (2003) Residual stresses and strains in orthogonal metal cutting, International Journal of Machine Tools and Manufacture. Elsevier Science Ltd, 43(6), pp. 573–587.
Shokrieh, M. M. and Ghanei Mohammadi, A. R. (2014) 2 - Destructive techniques in the measurement of residual stresses in composite materials: an overview, in Shokrieh, M. M. B. T.-R. S. in C. M. (ed.). Woodhead Publishing, pp. 15–57.
Swaminathan, S., Ravi Shankar, M., Rao, B., Compton, W., Chandrasekar, S., King, A. and Trumble, K. (2007) Severe plastic deformation (SPD) and nanostructured materials by machining, Journal of Materials Science. Springer Netherlands, 42(5), pp. 1529–1541.
Tang, Z. T., Liu, Z. Q., Pan, Y. Z., Wan, Y. and Ai, X. (2009) The influence of tool flank wear on residual stresses induced by milling aluminum alloy, Journal of Materials Processing Technology, 209(9), pp. 4502–4508.
To, S., Lee, W. B. and Cheung, C. F. (2003) Orientation changes of aluminium single crystals in ultra-precision diamond turning, Journal of Materials Processing Technology, 140(1–3), pp. 346–351.
To, S., Zhu, Y. H. and Lee, W. B. (2008) Effects of cutting depth on the surface microstructure of a Zn-Al alloy during ultra-precision machining, Applied Surface Science. Netherlands: Elsevier Science B.V., 254(6), pp. 1559–1564.
Treuting, R. G. and Read Jr., W. T. (1951) A mechanical determination of biaxial residual stress in sheet materials, Journal of Applied Physics, 22, pp. 130–134.
Triawan, F., Nandiyanto, A. B. D., Abdullah, A. G., and Aziz, M. (2018) Plasma nitriding time on the hardness and crystal structure/phase of SUS403 and SCS6 martensitic stainless steels: an analytical study. Journal of Engineering Science and Technology, 13(8), 2369-2378.
Turan, M. E., Aydin, F., Sun, Y. and Cetin, M. (2019) Residual stress measurement by strain gauge and X-ray diffraction method in different shaped rails, Engineering Failure Analysis, 96, pp. 525–529.
von Turkovich, B. F. and Field, M. (1981) Survey on material behaviour in machining, CIRP Annals - Manufacturing Technology, 30(2), pp. 533–540.
Ulutan, D., Erdem Alaca, B. and Lazoglu, I. (2007) Analytical modelling of residual stresses in machining, Journal of Materials Processing Technology. Elsevier Ltd, Oxford, OX5 1GB, United Kingdom, 183(1), pp. 77–87.
Walker, D. M. (2001) Residual stress measurement techniques, Advanced Materials & Processes.
Walton, H. (2002) Methods to estimate residual stress, in Totten, G. E., Howes, M. A. H., and Inoue, T. (eds) Handbook of residual stress and deformation of steel . Materials Park, Ohio : ASM International, c2002.
Wang, J., Zhang, D., Wu, B. and Luo, M. (2017) Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718 , Materials Research . scielo , pp. 1681–1689.
Xiang, Y., Teng, D., Deng, M., Li, Y., Liu, C. and Xuan, F. (2018) Characterization of Local Residual Stress at Blade Surfaces by the V(z) Curve Technique, Metals .
Yuan, X., Zhang, J., Lian, Y., Du, C., Xu, W., Zhao, Y. and Mo, J. (2018) Research progress of residual stress determination in magnesium alloys, Journal of Magnesium and Alloys, 6(3), pp. 238–244.
Zhou, J., Bushlya, V., Peng, R. L., Chen, Z., Johansson, S. and Stahl, J. E. (2014) Analysis of Subsurface Microstructure and Residual Stresses in Machined Inconel 718 with PCBN and Al2O3-SiCw Tools, Procedia CIRP, 13, pp. 150–155
Bifano, T. G. and Hosler, J. B. (1993) Precision grinding of ultra-thin quartz wafers, Transactions of the ASME. Journal of Engineering for Industry. USA, 115(3), pp. 258–262.
Brinksmeier, E. and Tönshoff, H. K. (1985) X-ray stress measurement -- a tool for the study and layout of machining processes, CIRP Annals - Manufacturing Technology, 34(1), pp. 485–490.
Campbell, C. E., Bendersky, L. A., Boettinger, W. J. and Ivester, R. (2006) Microstructural characterization of Al-7075-T651 chips and work pieces produced by high-speed machining, Materials Science and Engineering: A, 430(1–2), pp. 15–26.
Cullity, B. D. and Stock, S. R. (2001) Elements of X-ray Diffraction. 3rd edn. Upper Saddle River, New Jersey: Prentice Hall.
Dive, V., Lasurkar, S., Limaje, K. and Yash, K. (2017) Study Paper on Methods of Measurement of Residual Stress in Mechanical Components, International Journal for Research in Applied Science and Engineering Technology (IJRASET), 5(IV).
Fang, G. and Zeng, P. (2005) Three-dimensional thermo-elastic-plastic coupled FEM simulations for metal oblique cutting processes, Journal of Materials Processing Technology, 168(1), pp. 42–48.
Guo, Y. B., Ammula, S. C. and Barkey, M. E. (2006) A wet etching method coupled with finite element analysis-based compliance function to determine residual stress in high-speed milling, Transactions of the ASME. Journal of Manufacturing Science and Engineering. USA: ASME, 128(3), pp. 792–801.
Hanna, C. R. (2007) Engineering Residual Stress into the Workpiece through the Design of Machining Process Parameters. Georgia Institute of Technology.
He, Z.-H., Zhang, X.-M. and Ding, H. (2016) Comparison of Residual Stresses in Cryogenic and Dry Machining of Inconel 718, Procedia CIRP, 46, pp. 19–22.
Huang, X., Sun, J., Li, J., Han, X. and Xiong, Q. (2013) An Experimental Investigation of Residual Stresses in High-Speed End Milling 7050-T7451 Aluminum Alloy, Advances in Mechanical Engineering. SAGE Publications, 5, p. 592659.
Jacobus, K., DeVor, R. E. and Kapoor, S. G. (2000) Machining-induced residual stress: experimentation & modelling, Journal of Manufacturing Science and Engineering, Transactions of the ASME, 122, pp. 20–31.
Kuczmaszewski, J., Łogin, W., Pieśko, P. and Zagórski, I. (2018) State of Residual Stresses After the Process of Milling Selected Aluminium Alloys, Advances in Science and Technology Research Journal, 12(1), pp. 63–73.
Kudryavtsev, Y. F. (2008) Residual Stress BT - Springer Handbook of Experimental Solid Mechanics, in Sharpe, W. N. (ed.). Boston, MA: Springer US, pp. 371–388.
Lu, L., Hu, S., Liu, L. and Yin, Z. (2016) High speed cutting of AZ31 magnesium alloy, Journal of Magnesium and Alloys, 4(2), pp. 128–134.
Ma, Y., Feng, P., Zhang, J.,Wu, Z. and Yu, D. (2016) Prediction of surface residual stress after end milling based on cutting force and temperature, Journal of Materials Processing Technology, 235, pp. 41–48.
Ma, Y., Yu, D. W. and Feng, P. F. (2014) FEM Analysis of Residual Stress Distribution and Cutting Forces in Orthogonal Cutting with Different Initial Stresses, Materials Science Forum. Trans Tech Publications Ltd, 800–801, pp. 380–384.
Masmiati, N. and Sarhan, A. A. D. (2015) Optimizing cutting parameters in inclined end milling for minimum surface residual stress – Taguchi approach, Measurement, 60, pp. 267–275.
Mehmet E. Kartal (2013) Analytical solutions for determining residual stresses in two-dimensional domains using the contour method, Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences. Royal Society, 469(2159), p. 20130367.
Nurprasetio, I. P., Budiman, B. A., and Triawan, F. (2017) Failure investigation of plastic shredding machine’s flange coupling based on mechanical analysis. Indonesian Journal of Science and Technology, 2(2), 124-133.
Perez, I., Madariaga, A., Cuesta, M., Garay, A., Arrazola, P. J., Ruiz, J. J., Rubio, F. J. and Sanchez, R. (2018) Effect of cutting speed on the surface integrity of face milled 7050-T7451 aluminium workpieces, Procedia CIRP, 71, pp. 460–465.
Prevey, P. S. (1986) X-ray diffraction residual stress techniques, in Metals Handbook. American Society for Metals, pp. 380–392.
Ramesh, K., Huang, H., Yin, L. and Yui, A. (2004) Surface waviness controlled grinding of thin mold inserts using chilled air as coolant, Materials and Manufacturing Processes. USA: Marcel Dekker, 19(2), pp. 341–354.
Rathbun, J. F. O. and Coffin, J. L. F. (1966) Experimental investigation of residual stress in quenched flat plates, Experimental Mechanics, 6(10), pp. 519–527.
Reimer, A. and Luo, X. (2018) Prediction of residual stress in precision milling of AISI H13 steel, Procedia CIRP, 71, pp. 329–334.
Robinson, J., Tanner, D., Truman, C. and Wimpory, R. (2011) Measurement and prediction of machining induced redistribution of residual stress in the aluminium alloy 7449, Experimental Mechanics. Springer Boston, 51(6), pp. 981–993.
Ruud, C. O. (1986) Residual stress measurements, in ASM handbook / prepared under the direction of the ASM International Handbook Committee. Materials Park, OH : ASM International, 1986-.
Saldana, C., Swaminathan, S., Brown, T. L., Moscoso, W., Mann, J. B., Compton, W. D. and Chandrasekar, S. (2010) Unusual applications of machining: controlled nanostructuring of materials and surfaces, Journal of Manufacturing Science and Engineering. ASME, 132(3), pp. 30908–30912.
Šarga, P. and Menda, F. (2013) Comparison of Ring-Core Method and Hole-drilling Method Used for Determining Residual Stresses, American Journal of Mechanical Engineering. Science and Education Publishing, 1(7), pp. 335–338.
Schajer, G. (2010) Relaxation methods for measuring residual stresses: techniques and opportunities, Experimental Mechanics. Springer Boston, 50(8), pp. 1117–1127.
Sharman, A. R. C., Hughes, J. I. and Ridgway, K. (2006) An analysis of the residual stresses generated in Inconel 718 when turning, Journal of Materials Processing Technology. Switzerland: Elsevier, 173(3), pp. 359–367.
Shaw, M. C. (1984) Metal cutting principles, Oxford Series on Advanced Manufacturing. Edited by 3. Oxford: Oxford University Press.
Shet, C. and Deng, X. (2003) Residual stresses and strains in orthogonal metal cutting, International Journal of Machine Tools and Manufacture. Elsevier Science Ltd, 43(6), pp. 573–587.
Shokrieh, M. M. and Ghanei Mohammadi, A. R. (2014) 2 - Destructive techniques in the measurement of residual stresses in composite materials: an overview, in Shokrieh, M. M. B. T.-R. S. in C. M. (ed.). Woodhead Publishing, pp. 15–57.
Swaminathan, S., Ravi Shankar, M., Rao, B., Compton, W., Chandrasekar, S., King, A. and Trumble, K. (2007) Severe plastic deformation (SPD) and nanostructured materials by machining, Journal of Materials Science. Springer Netherlands, 42(5), pp. 1529–1541.
Tang, Z. T., Liu, Z. Q., Pan, Y. Z., Wan, Y. and Ai, X. (2009) The influence of tool flank wear on residual stresses induced by milling aluminum alloy, Journal of Materials Processing Technology, 209(9), pp. 4502–4508.
To, S., Lee, W. B. and Cheung, C. F. (2003) Orientation changes of aluminium single crystals in ultra-precision diamond turning, Journal of Materials Processing Technology, 140(1–3), pp. 346–351.
To, S., Zhu, Y. H. and Lee, W. B. (2008) Effects of cutting depth on the surface microstructure of a Zn-Al alloy during ultra-precision machining, Applied Surface Science. Netherlands: Elsevier Science B.V., 254(6), pp. 1559–1564.
Treuting, R. G. and Read Jr., W. T. (1951) A mechanical determination of biaxial residual stress in sheet materials, Journal of Applied Physics, 22, pp. 130–134.
Triawan, F., Nandiyanto, A. B. D., Abdullah, A. G., and Aziz, M. (2018) Plasma nitriding time on the hardness and crystal structure/phase of SUS403 and SCS6 martensitic stainless steels: an analytical study. Journal of Engineering Science and Technology, 13(8), 2369-2378.
Turan, M. E., Aydin, F., Sun, Y. and Cetin, M. (2019) Residual stress measurement by strain gauge and X-ray diffraction method in different shaped rails, Engineering Failure Analysis, 96, pp. 525–529.
von Turkovich, B. F. and Field, M. (1981) Survey on material behaviour in machining, CIRP Annals - Manufacturing Technology, 30(2), pp. 533–540.
Ulutan, D., Erdem Alaca, B. and Lazoglu, I. (2007) Analytical modelling of residual stresses in machining, Journal of Materials Processing Technology. Elsevier Ltd, Oxford, OX5 1GB, United Kingdom, 183(1), pp. 77–87.
Walker, D. M. (2001) Residual stress measurement techniques, Advanced Materials & Processes.
Walton, H. (2002) Methods to estimate residual stress, in Totten, G. E., Howes, M. A. H., and Inoue, T. (eds) Handbook of residual stress and deformation of steel . Materials Park, Ohio : ASM International, c2002.
Wang, J., Zhang, D., Wu, B. and Luo, M. (2017) Residual Stresses Analysis in Ball end Milling of Nickel-Based Superalloy Inconel 718 , Materials Research . scielo , pp. 1681–1689.
Xiang, Y., Teng, D., Deng, M., Li, Y., Liu, C. and Xuan, F. (2018) Characterization of Local Residual Stress at Blade Surfaces by the V(z) Curve Technique, Metals .
Yuan, X., Zhang, J., Lian, Y., Du, C., Xu, W., Zhao, Y. and Mo, J. (2018) Research progress of residual stress determination in magnesium alloys, Journal of Magnesium and Alloys, 6(3), pp. 238–244.
Zhou, J., Bushlya, V., Peng, R. L., Chen, Z., Johansson, S. and Stahl, J. E. (2014) Analysis of Subsurface Microstructure and Residual Stresses in Machined Inconel 718 with PCBN and Al2O3-SiCw Tools, Procedia CIRP, 13, pp. 150–155
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2019-09-30
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How to Cite
A Review on Measurement Methods for Machining Induced Residual Stress (K. Saptaji, S. N. Afiqah, & R. D. Ramdan , Trans.). (2019). Indonesian Journal of Computing, Engineering, and Design (IJoCED), 1(2), 106-120. https://doi.org/10.35806/ijoced.v1i2.64
