Effects of cutting parameters on surface residual stress and its mechanism in high-speed milling of TB6

Formation mechanism and influence of cutting parameters on residual stress in flank milling of TB6 are investigated through orthogonal experiments. The thermal-mechanical coupling effect on forming residual stress is studied by analyzing the microstructure of metamorphic layer. Experiment results show that cutting temperature varies between 300 degrees C and 518 degrees C under experiment conditions, while residual compressive stress on machined surface is -199.8 to -41.7 MPa. Tensile residual stress occurs on subsurface when increasing milling parameters excessively. When cutting TB6 with parameters of f(z) = 0.02 mm/z, v(c) = 60 m/min, a(e) = 0.2 mm and a(p) = 10 mm, only the compressive residual stress can be detected, which is good for its fatigue life. The depth of compressive residual stress layer is 10-20 mu m.