Regular Article

Analytical modeling of residual stress in end-milling with minimum quantity lubrication

¹ Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA
² Metal Industries Research and Development Centre (MIRDC), Kaohsiung, Taiwan

^* e-mail: lingercai@gatech.edu
^** e-mail: steven.liang@me.gatech.edu

Received: 11 June 2021
Accepted: 11 January 2022

Abstract

Milling with minimum quantity lubrication (MQL) is now a commonly used machining technique in industry. This paper proposed an analytical model for residual stress prediction in milling with MQL based on chip formation orthogonal cutting model and boundary lubrication effect. The effect of lubrication is considered to the change of friction coefficients and the heat loss at the flank surface, which would further affect the prediction of the cutting force and temperature. The proposed model is validated with experimental data done to AZ61A magnesium alloy and obtained a reasonable validation result. The predictive results show at the case investigated, neither feed per tooth nor depth of cut has a significant influence to the general trend of residual stress, where at the surface the residual stress is highly tensile and come to compressive at deeper depth. However, the application of MQL is shown to be able to significantly reduce the average magnitude of the residual stress.