Influence of Cutting Parameters on Residual Stresses Induced by Milling in Pressure Die-Cast Aluminum Alloy Components

Abstract

Residual stress states, induced by milling in a die cast aluminum alloy component, have been determined by means of X-ray diffraction. Samples have been cut from an automotive engine sump, fabricated by pressure die-casting. The X-ray experimental apparatus has been calibrated by detecting stresses on a sample bent under imposed external deformations. Different samples (cut from the sump) have been tested after milling operations with each one characterized by different cutting speed, feed speed and depth of cut in order to evaluate their influence on the final residual stress state. Results have been analyzed taking into account surface morphologies after milling, as revealed by scanning electron microscopy.