Experimental Analysis, FE Prediction, and Multi-criteria Optimization of Residual Stresses Induced by Rough Milling Processes in Large Steel Blocks

The milling process is an industrial manufacturing method commonly used for shaping custom parts with precise tolerances using rotary cutters. Rough Milling processes affect the part quality of machined components due to high temperature, large strain, and high strain rate. It is important to identify and improve the milling-induced residual stresses of surface and subsurface layers for crack prevention.
Finkl Steel-Sorel manufactures blocks of steel in several steps including casting, forging, quenching, tempering, and lastly dry rough milling. According to the company, cracks are observed in the blocks during after milling processes. These cracks may be due to the presence of surface and sub-surface tensile residual stresses induced by the machining processes.
This study is aimed at studying (experimentally and numerically) in order to optimise the machining conditions so as to control residual stresses induced by the rough milling process and by doing so minimize the cracking occurrence.
The developed experimental and numerical models of the rough milling process will be given to Finkl Steel-Sorel as tools to predict and optimized the machining conditions for large blocks: residual stresses, tool life, and material removal rate.

Intern: 
Mahshad Javidikia
Superviseur universitaire: 
Victor Songmene;Mohammad Jahazi
Province: 
Quebec
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