Skip to main content
SpringerLink
Log in

Determination of surface and in-depth residual stress distributions induced by hard milling of H13 steel

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

In the present study, an experimental investigation was conducted to determine the effects of surface texture, cutting parameters and phase transformation on the surface and in-depth residual stress distributions induced by hard milling of AISI H13 steel (50 ± 1HRc) with the coated carbide tools. The results show that the surface residual stress distribution between two adjacent machined lays has the same periodic variational regularity as the surface profiles, which means that the surface residual stress distribution has a high correlation with the machined surface texture. Surface residual stresses in the pick direction are much more compressive than that in the feed direction; at the same time, radial depth of cut and feed are the main cutting parameters affecting surface residual stresses. Very thin white layer forms or even no obvious microstructural alteration appears in the subsurface. Phase transformations of the subsurface material deeply affect the in-depth residual stress distribution, a ‘hook’ shaped residual stress profile beneath the machined surface is generated in which the maximum compressive stresses occur at the depth of 3–18 μm below the surface.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Jing LL, Liu G, Chen M (2006) Study on surface integrity in hard milling of hardened die steel. Mat Sci Forum 532–533:540–543

    Article  Google Scholar 

  2. König W, Berktold A, Koch KF (1993) Turning versus grinding—a comparison of surface integrity aspects and attainable accuracies. CIRP Ann Manuf Technol 42:39–43

    Article  Google Scholar 

  3. Srivastava A, Joshi V, Shivpuri R (2004) Computer modeling and prediction of thermal fatigue cracking in die–casting tooling. Wear 256:38–43

    Article  Google Scholar 

  4. Wu DW, Matsumoto Y (1990) Effect of hardness on residual stress in orthogonal machining of AISI 4340 steel. J Eng Ind (Trans ASME) 112:245–252

    Article  Google Scholar 

  5. Rhyim YM, Youn KT, Yoo WD, Na YS, Lee JH (2004) Thermal fatigue behavior of the surface treated hot die steel depending on test temperature. Mat Sci Forum 449–452:869–873

    Article  Google Scholar 

  6. Zhu L, Tao XY, Cengdian L (1998) Fatigue strength and crack propagation life of in-service high pressure tubular reactor under residual stress. Int J Press Vessels Piping 75:871–877

    Article  Google Scholar 

  7. Moshier MA, Hillberry BM (1999) The inclusion of compressive residual stress effects in crack growth modeling. Fatigue Fract Eng Mater Struct 22:519–526

    Article  Google Scholar 

  8. Brinksmeier E, Cammett JT, König W, Leskovar P, Peters J, Tönshoff HK (1982) Residual stress–measurement and causes in machining processes. CIRP Ann 31:491–510

    Article  Google Scholar 

  9. Sai WB, Salah NB, Lebrun JL (2001) Influence of machining by finishing milling on surface characteristics. Int J Mach Tools Manuf 41:443–450

    Article  Google Scholar 

  10. Thiele JD, Melkote SN (1999) The effect of tool edge geometry on workpiece sub-surface deformation and through-thickness residual stress for hard turning of AISI 52100 steel. Trans NAMRI/SME 27:135–140

    Google Scholar 

  11. König W, Klinger M, Link R (1990) Machining hard materials with geometrically defined cutting edges-Field of applications and limitations. CIRP Ann 39:61–64

    Article  Google Scholar 

  12. Dahlman P, Gunnberg F, Jacobson M (2004) The influence of rake angle, cutting feed and cutting depth on residual stress in hard turning. J Mater Process Technol 147:181–184

    Article  Google Scholar 

  13. Axinte DA, Dewes RC (2002) Surface integrity of hot work tool steel after high speed milling–experimental data and empirical models. J Mater Process Technol 127:325–335

    Article  Google Scholar 

  14. Ding TC, Zhang S, Lv HG, Xu XL (2011) A comparative investigation on surface roughness and residual stress during end-milling AISI H13 steel with different geometrical inserts. Mat Manuf Proc 26:1085–1093

    Article  Google Scholar 

  15. Tönshoff HK, Arendt C, Amor RB (2000) Cutting of hardened steel. CIRP Ann Manuf Technol 49:547–566

    Article  Google Scholar 

  16. Dogra M, Sharma V, Sachdeva A, Suri NM (2012) Tool life and surface integrity issues in continuous and interrupted finish hard turning with coated carbide and CBN tools. Proc Inst Mech Eng B J Eng Manuf 226:431–444

    Article  Google Scholar 

  17. Guo YB, Warren AW, Hashimoto F (2010) The basic relationships between residual stress, white layer, and fatigue life of hard turned and ground surfaces in rolling contact. CIRP J Manuf Sci Technol 2:129–134

    Article  Google Scholar 

  18. Caruso S, Umbrello D, Outeirob JC, Filice L, Micari F (2011) An experimental investigation of residual stresses in hard machining of AISI 52100 steel. Procedia Eng 19:67–72

    Article  Google Scholar 

  19. Gohar R, Rahnejat H (2008) Fundamentals of tribology. London Imperial College Press, London

    Book  MATH  Google Scholar 

  20. Toh CK (2004) Surface topography analysis in high speed finish milling inclined hardened steel. Precis Eng 28:386–398

    Article  Google Scholar 

  21. Chen JS, Huang YK, Chen MS (2005) A study of the surface scallop generating mechanism in the ball-end milling process. Int J Mach Tools Manuf 45:1077–1084

    Article  Google Scholar 

  22. Stephenson DA, Agapiou J (2005) Metal cutting theory and application, 2nd edn. Taylor & Francis, New York

    Google Scholar 

  23. Thomas TR, Rosen BG, Amini N (1999) Fractal characterization of the anisotropy of rough surfaces. Wear 232:41–50

    Article  Google Scholar 

  24. Ghanem F, Braham C, Fitzpatrick ME, Sidhom H (2002) Effect of near-surface residual stress and microstructure modification from machining on the fatigue endurance of a tool steel. J Mater Eng Perform 11(6):631–639

    Article  Google Scholar 

Download references

Acknowledgments

This research is based upon work supported by the National Natural Science Foundation of China (Grant No. 51175309), and Taishan Scholar Program Foundation of Shandong.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Shandong University, Jinan, 250061, China

    S. Zhang & J. F. Li

  2. Changchun Institute of Optics, Fine Mechanics and Physics, 3888 Dong Nanhu Road, Changchun, 130033, China

    T. C. Ding

Authors
  1. S. Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. T. C. Ding
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. J. F. Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S. Zhang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Zhang, S., Ding, T.C. & Li, J.F. Determination of surface and in-depth residual stress distributions induced by hard milling of H13 steel. Prod. Eng. Res. Devel. 6, 375–383 (2012). https://doi.org/10.1007/s11740-012-0390-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-012-0390-x

Keywords

Search

Navigation