In milling, one of the main concerns is the tendency of introducing high magnitude tensile residual stresses in the machined surface, very harmful against fatigue. To assure a high surface integrity without postprocessing operations, a new approach is proposed: milling under an externally applied bending load. This article presents a simple fixture design to efficiently achieve this objective, and the experimental validation of the introduced residual stresses using this method limited to the analysis of pocket milling operations in aluminium alloy. This research showed positive results introducing compressive residual stresses and reducing cutting forces during milling using the proposed fixture.
Science Journal 