Analysis of Residual Stress States of Structured Surfaces Manufactured by High-Feed and Micromilling

Abstract

Abstract The performance of technological surfaces can be optimized via tailored characteristics according to their specific field of usage. These high performance surfaces are needed for the new technology of Sheet-Bulk Metal Forming (SBMF), which is a combination of sheet metal and bulk forming operations. Due to the high surface loads of bulk forming operations, tool surfaces need to be capable to withstand high stress states. Additional to a high wear resistance, the friction coefficient of these surfaces is an important criterion for the material flow of the sheet material. Surface characteristics can be adjusted by using technologies such as high-feed and micromilling processes resulting in different friction coefficients optimizing functional performance of the tools. In dependency of these different manufacturing processes, different residual stresses are induced into the subsurface of the forming tool. Reliability of residual stress measurements via X-ray diffractometry for microstructured surfaces produced through high-feed milling and micromilling is investigated.