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General Information
    • ISSN: 1793-8198 (Print)
    • Abbreviated Title: Int. J. Mater. Mech. Manuf.
    • Frequency: Bimonthly
    • DOI: 10.18178/IJMMM
    • Editor-in-Chief: Prof. Ian McAndrew
    • Co-editor-in-Chief: Prof. K. M. Gupta
    • Executive Editor: Cherry L. Chen
    • Abstracting/Indexing: Inspec (IET), Chemical Abstracts Services (CAS),  ProQuest, Crossref, Ulrich's Periodicals Directory,  EBSCO.
    • E-mail ijmmm@ejournal.net

Prof. Ian McAndrew
Capitol Technology University, USA
It is my honor to be the editor-in-chief of IJMMM. I will do my best to work with the editorial team and help make this journal better.

IJMMM 2018 Vol.6(2): 88-93 ISSN: 1793-8198
DOI: 10.18178/ijmmm.2018.6.2.353

Effect of Cusp Size, Depth and Direction on Stress Concentration

Md Shams E. Tabriz and Simon Barrans
Abstract—Recently multi-axial machining technology has improved significantly. It has become a widely accepted method of manufacturing components with complex, free form surfaces. Solid billet materials with negligible internal defects are used in this process. This provides increased durability and fatigue life over equivalent cast components. However, multi-axial machining leaves cusps as machining marks. The combination of tool size and step-over generates cusps with different depths and widths. Even though the cusps add extra material on top of the nominal surface, the Finite Element Analysis simulations presented in this paper show that the maximum stress generated within the cusps can be greater than that predicted from the cusp-free geometry. These stress concentrations generated by cusps can reduce the fatigue life and durability of a machined component. In this paper a full factorial analysis of the effect of tool size, cusp width/step-over and cusp direction has been conducted. The analysis uses five different levels of tool size and cusps width and four levels of cusp direction. The results can be used to determine a tool size, cusp width and cusp direction combination with minimum spurious stress raising effect.

Index Terms—Cusp depth, cusp direction, cusp size, finite element analysis, stress concentration.

The authors are with the University of Huddersfield, Huddersfield, United Kingdom (e-mail: Md.S.Tabriz@hud.ac.uk, S.Barrans@hud.ac.uk).


Cite: Md Shams E. Tabriz and Simon Barrans, "Effect of Cusp Size, Depth and Direction on Stress Concentration," International Journal of Materials, Mechanics and Manufacturing vol. 6, no. 2, pp. 88-93, 2018.

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