Mapping of Superficial Residual Stresses in Machined Components

  • John E. Wyatt (Mississippi State University)
  • John T. Berry (Mississippi State University)


The paper describes how the superficial residual elastic strains present after machining AA 6061-T6511 bar stock using a 63.5 mm (2½”) diameter face mill at various cutting speeds were measured using a recently developed low cost technique intended for workshop use. The technique enables the distribution of such strains to be mapped over a wide area by following the change in spacing of a previously generated grid of hardness indents, which have been placed on the components, then examined after stress relieving. The in- dents were generated using an indenter attached to the spindle of the machining center upon which the samples were machined. A microscope also mounted on the spindle, to which a video camera was attached, facilitated this measurement. Finite Element Analysis (FEA) was not employed in this series of experiments as this is a preliminary investigation. The results reveal a consistent pattern of residual strains which vary between tensile and compressive forces as the cutter rotates.

Keywords: manufacturing|materials and processes|materials testing

How to Cite:

Wyatt, J. E. & Berry, J. T., (2009) “Mapping of Superficial Residual Stresses in Machined Components”, Journal of Industrial Technology 25(4).

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Published on
01 Oct 2009