Abstract—The aim of this research was to investigate the residual stresses in an aluminum alloy Al-6061 workpiece after machining. The sensitivity of residual stresses to cutting speed and feed rate was determined using finite element method. Tensile residual stresses at the surface of components are generally undesirable as they contribute to fatigue failure, quench cracking and stress-corrosion cracking. A two dimensional model of machining was developed using commercially available finite element software, Abaqus, to simulate orthogonal cutting of Al-6061 alloy. Numerical simulations of orthogonal cutting of the workpiece were carried out at various preselected combinations of feed rate and cutting speed. The simulation results showed that residual stresses were insensitive to changes in cutting speed, however, residual stresses were clearly affected by the change in feed rate.
Index Terms—Finite element method, machining, orthogonal cutting, residual stresses.
Sohail Akram is with the School of Mechanical & Manufacturing Engineering (SMME), National University of Science and Technology (NUST), Islamabad, Pakistan (e-mail: sohailakram77@yahoo.com).
Syed Husain Imran Jaffery, Mushtaq Khan, and Liaqat Ali are with the Department of Design and Manufacturing, School of Mechanical & Manufacturing Engineering (SMME), National University of Science and Technology (NUST), Islamabad, Pakistan (e-mail: {Imran, mkhan, aamirmub}@smme.nust.edu.pk).
Aamir Mubashar is with the Department of Mechanical Engineering, School of Mechanical & Manufacturing Engineering (SMME), National University of Science and Technology (NUST), Islamabad, Pakistan.
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Cite: Sohail Akram, Syed Husain Imran Jaffery, Mushtaq Khan, Aamir Mubashar, and Liaqat Ali, "A Numerical Investigation of Effects of Cutting Velocity and Feed Rate on Residual Stresses in Aluminum Alloy Al-6061," International Journal of Materials, Mechanics and Manufacturing vol. 3, no. 1, pp. 26-30, 2015.
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