Experimental Investigation of the Influence of Milling Conditions on Residual Stress in the Surface Layer of an Aerospace Aluminum Alloy

In this study, the correlations between milling conditions—namely, the cutting tool feed direction relative to the rolling direction, the milling type, the coolant application, as well as the cutting speed—and the surface residual stress of a selected aluminum alloy (2024 T351) were investigated. Determining the type and magnitude of residual stress is of paramount importance as this stress is among the primary causes of post-machining strain of thin-walled components. On the basis of the experimental results, it was found that all factors analyzed significantly affect the residual stress state. Specifically, milling in the parallel direction induces lower residual tensile stress compared to milling in the perpendicular direction. Analogously, up-milling yields lower tensile residual stress than down-milling, and flood cooling leads to lower tensile residual stress than MQL. It was clearly confirmed that as cutting speed increases, tensile residual stress also increases, but only up to a certain threshold; once the high-speed cutting regime is reached, tensile residual stress begins to decrease. Consequently, the proper selection of milling parameters is a crucial consideration for optimizing machining processes and minimizing machining-induced residual stress.