Residual Stress Analysis of Mild Steel ASTM A36 in Milling&Drilling

The significance of machining parameter optimization is increasing day by day in the current manufacturing scenario. Many large industries have attempted to introduce the highly automated and computer-controlled machines as their strategy to adapt to the ever-changing competitive market requirement. Due to high capital and machining costs, there is an economic need to operate these machines as efficiently as possible in order to obtain the required pay back. This research looks to fill gaps in current residual stress modeling techniques. In particular, the research will focus on predicting residual stresses in milling and drilling process. Mild steel ASTM A36 is the material used here. An investigation on influence of machining parameters such as number of teeth of the cutter (Zc) and depth of cut (t) for milling, feed (S) and diameter of drill bit (d) for drilling. These parameters have large influence on the cutting force, and the response parameter is the residual stress. Experiments were conducted. Effects of input parameters on output responses were studied. The simulation is carried out with ANSYS workbench. And finally optimal parameter combination in milling and drilling is obtained.