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This publication is a result of the project entitled “Development of the milling technique of thin-walled integral elements made of aviation light metal alloys in the context of minimalisation post-machining deformations,” contract number: LIDER14/0153/2023; total project value:1,543,750.00 PLN. This project is financed by the National Centre for Research and Development under the 14th edition of the LIDER Programme.
In this study, the correlations between milling conditions—namely, the cutting
tool feed direction relative to the rolling direction, the milling type, the coolant applica-
tion, as well as the cutting speed—and the surface residual stress of a selected aluminum
alloy (2024 T351) were investigated. Determining the type and magnitude of residual
stress is of paramount importance as this stress is among the primary causes of post-ma-
chining strain of thin-walled components. On the basis of the experimental results, it was
found that all factors analyzed significantly affect the residual stress state. Specifically,
milling in the parallel direction induces lower residual tensile stress compared to milling
in the perpendicular direction. Analogously, up-milling yields lower tensile residual
stress than down-milling, and flood cooling leads to lower tensile residual stress than
MQL. It was clearly confirmed that as cutting speed increases, tensile residual stress also
increases, but only up to a certain threshold; once the high-speed cutting regime is
reached, tensile residual stress begins to decrease. Consequently, the proper selection of
milling parameters is a crucial consideration for optimizing machining processes and min-
imizing machining-induced residual stress.
