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 °C and 518 °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 µm.