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Formation of Compressive Residual Stress by Face Milling Steel AISI 1045
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Abstract

     Machining residual stresses correlate very closely with the cutting parameters and the tool geometries. This research work aims to investigate the effect of cutting speed, feed rate and depth of cut on the surface residual stress of steel AISI 1045 after face milling operation. After each milling test, the residual stress on the surface of the workpiece was measured by using X-ray diffraction technique. Design of Experiment (DOE) software was employed using the response surface methodology (RSM) technique with a central composite rotatable design to build a mathematical model to determine the relationship between the input variables and the response. The results showed that both the feed rate and the cutting speed are the significant factors controlling the surface residual stress, while the depth of cut had no influence. A quadratic empirical model was developed with a 95% confidence level, and a good agreement was found between the experimental and predicted results. A numerical optimization was then conducted through DOE program to find the optimum surface residual stress at the optimum cutting parameters, depending on the maximum desirability obtained. The optimum compressive surface residual stress (-224.361 MPa) was found at cutting speed of 69.2 m/min, feed rate of 0.4 m/min and depth of cut of 0.4 mm.

Keywords: Face milling, Cutting parameters, Steel AISI 1045, Residual stresses, XRD; DOE, RSM, Modeling and Numerical optimization.

 

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Publication Date
Mon Mar 11 2019
Journal Name
Baghdad Science Journal
Experimental and Quantum Chemical Studies on the Corrosion Inhibition of Mild Steel By 2-((Thiophen-2-Ylmethylene) Amino)Benzenethio in 1M HCl
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The impact of a Schiff base namely 2-((thiophen-2-ylmethylene)amino)benzenethiol  to corrode mild steel in 1 M HCl  resolved was evaluated using different weight loss technique and scanning electron microscopy (SEM).different weight measurements to expand that the 2-((thiophen-2-ylmethylene) amino) benzenethiol  inhibits  the corrosion of mild steel through adsorbing  of  top for mild steel and block the active locality. The inhibitive impacts of 2-((thiophen-2-ylmethylene)amino)benzenethiol  increase with increasing concentration and decrease with increasing temperature. SEM to checking revealed that the alloy surface was quite unaffected and formed protective film on its surface. The investigated

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Scopus (4)
Crossref (1)
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Publication Date
Tue Jun 01 2021
Journal Name
Journal Of Advanced Joining Processes
Coupled Eulerian–Lagrangian prediction of thermal and residual stress environments in dissimilar friction stir welding of aluminum alloys
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The evaluation of residual stresses (RS) induced by the friction stir welding (FSW) process is crucial in anticipating the performance of the welded structure. The existence of such residual stresses within a friction stir welded structure may lead to excessive distortion and weakness to afford the applied external loads. To assess quantitatively the effect of these residual stresses generated by FSW process, the current paper implements a Coupled Eulerian–Lagrangian (CEL) finite element simulation to analyze both thermal and subsequent resulted remaining stress environments in dissimilar friction stir welding of AA6061-T6 and AA2024-T3 alloys. The thermal analysis step was conducted first and followed by a mechanical analysis step in whi

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Scopus (67)
Crossref (45)
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Publication Date
Fri Jan 01 2021
Journal Name
Journal Of Mechanical Engineering Research And Developments
Fatigue life of welded joint improvement with various welding principles and shot peening process for AISI 1020 low carbon steel
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Scopus
Publication Date
Mon Jan 08 2018
Journal Name
International Journal Of Science And Research
effect of steel fiber type on compressive strength and modules of rupture on reactive powder concrete
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Publication Date
Thu Jul 04 2019
Journal Name
International Journal Of Automotive And Mechanical Engineering
Nonlinear Buckling Analysis of Steel Cylindrical Shell with Elliptical Cut-out Subjected to Longitudinal Compressive Load
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The current paper investigates the effect of cut-out design parameters on load-bearing capacity and buckling behaviour of steel cylindrical shell using a nonlinear finite element analysis in modelling cylinder buckling under longitudinal compressive load. The effect of four geometry design parameters: shell diameter to thickness ratio, cut-out location, orientation, and size were investigated in this study. To enhance the prediction of buckling behaviour, both geometrical and material nonlinearities were considered. An ANSYS APDL code was written and tested by verifying its validity through comparison with former buckling study. The results showed that changing the cut-out location from mid-height of the cylindrical shell towards a

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Crossref (2)
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Publication Date
Sat Apr 01 2017
Journal Name
Image & Video Processing
Enhancement of LBP-based face identification system by adopting preprocessing techniques
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Face Identification system is an active research area in these years. However, the accuracy and its dependency in real life systems are still questionable. Earlier research in face identification systems demonstrated that LBP based face recognition systems are preferred than others and give adequate accuracy. It is robust against illumination changes and considered as a high-speed algorithm. Performance metrics for such systems are calculated from time delay and accuracy. This paper introduces an improved face recognition system that is build using C++ programming language with the help of OpenCV library. Accuracy can be increased if a filter or combinations of filters are applied to the images. The accuracy increases from 95.5% (without ap

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Publication Date
Tue Jul 01 2014
Journal Name
International Journal Of Artificial Intelligence And Mechatronics
Building a Three-Axis CNC Milling Machine Control System
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CNC machines are widely used in production fields since they produce similar parts in a minimum time, at higher speed and with possibly minimum error. A control system is designed, implemented and tested to control the operation of a laboratory CNC milling machine having three axes that are moved by using a stepper motor attached to each axis. The control system includes two parts, hardware part and software part, the hardware part used a PC (works as controller) connected to the CNC machine through its parallel port by using designed interface circuit. The software part includes the algorithms needed to control the CNC. The sample needs to be machined is drawn by using one of the drawing software like AUTOCAD or 3D MAX and is saved in a we

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Publication Date
Mon Jan 12 2026
Journal Name
Infrastructures
Behaviour of Shear Stress Distribution in Steel Sections Under Static and Dynamic Loads
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Shear lag is the phenomenon that occurs when a supported slender member undergoes deformation from lateral loading, causing in-plane non-uniform distribution of stresses that results in reducing the member’s minimum strength capacity. This paper investigates the behaviour of shear distribution in steel I-section and box girders when subjected to both static and impact loadings. Three-dimensional finite element analysis models were prepared in Strand7 and validated against experimental results providing a basis for further comparison research into shear lagging effects. A parametric study was conducted comparing the effects of impact loading through certain specified velocities at the midspan of restrained ends. It provided new ins

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Publication Date
Tue Nov 01 2022
Journal Name
Aci Structural Journal
Stress at Ultimate in Internally Unbonded Steel Based on Genetic Expression Programming
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Publication Date
Tue Jul 01 2014
Journal Name
International Journal Of Artificial Intelligence And Mechatronics
Machining Polylines and Ellipses using Three-Axis CNC Milling Machine
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CNC machine is used to machine complex or simple shapes at higher speed with maximum accuracy and minimum error. In this paper a previously designed CNC control system is used to machine ellipses and polylines. The sample needs to be machined is drawn by using one of the drawing software like AUTOCAD® or 3D MAX and is saved in a well-known file format (DXF) then that file is fed to the CNC machine controller by the CNC operator then that part will be machined by the CNC machine. The CNC controller using developed algorithms that reads the DXF file feeds to the machine, extracts the shapes from the file and generates commands to move the CNC machine axes so that these shapes can be machined.

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