Development of a Finite Element Models and Method for Determining Residual Stresses in the Workpiece after the End Milling Operation

Abstract-The article presents a method that allows determining the magnitude, sign and nature of the distribution of residual stresses formed in the surface layer of workpieces during end milling operations. The method is based on a finite element models developed in the FE analysis programs, in a module that allows to solve problems in the formulation of Explicit Dynamics and CFD. The adequacy of the model was verified by comparing the results obtained from the conducted field experiments, based on the result of which regression models were compiled and exponential dependences were obtained, which made it possible to determine the value of the maximum residual stresses and surface roughness. Comparison of the numerical and field experiments showed that the discrepancy does not exceed 12.7% over the entire range of processing modes used in the field experiment.