Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy

Sunday J. Ojolo; Ifeoluwa J. Orisaleye; Nnaemeka Obiajulu

doi:doi:10.11648/j.ijmsa.20140306.27

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Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy

Sunday J. Ojolo, Ifeoluwa J. Orisaleye, Nnaemeka Obiajulu

Published in International Journal of Materials Science and Applications (Volume 3, Issue 6)

Received: 25 November 2014 Accepted: 4 December 2014 Published: 8 December 2014

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Abstract

Machining involves the thermal, elastic and plastic deformations of the surface layer which result in strain hardening, structural changes and development of residual stresses. These cause surface irregularities which may increase the risk of fatigue failure of material during usage. This study involves the investigation of the influence of cutting speed, feed rate and tool geometry on the fatigue life of end-milled specimens of 2024-aluminium alloy using a design of experiment approach. The experimental design constructed was such that the specimens were subjected to different machining conditions. Data analysis was carried out with Relia Soft OfficeTM 7 DOE++ software and Analysis of Variance (ANOVA). The study showed that by decreasing the feed rate (from 60mm/min to 7mm/min) and increasing the cutting speed (from 3.77m/min to 48.25m/min) significantly resulted in a higher fatigue life (from 1.93x103 cycles to 2.53x103 cycles). Whereas, the rake angle had the least significant effect on the fatigue life, it was discovered that the feed rate was found to be the most influential factor.

Published in	International Journal of Materials Science and Applications (Volume 3, Issue 6)
DOI	10.11648/j.ijmsa.20140306.27
Page(s)	391-398
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2024. Published by Science Publishing Group

Keywords

End-Milling, Machining Variables, Tool Geometry, Design of Experiments, Analysis of Mean, ANOVA

References

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[2]	J.D. Thiele, S.N. Melkote, R.A. Peascoe, and T.R. Watkins, “Effect of cutting edge geometry and workpiece hardness on surface residual stresses in finish turning of AISI 52100 steel”, J. Manuf. Sci. Eng., 122(4) (2000), 642-649.
[3]	Yukitaka, M. (2002), Metal Fatigue: Effects of small defects and non-metallic inclusions (Kyushu University, Japan), Elsevier, 2002.
[4]	D. Novovic, R.C. Dewes, D.K. Aspinwal, W. Voice, and P. Bowen, (2004) “The Effect of Machined Topography and Integrity on Fatigue Life”, International Journal of Machine Tools &Manufacture, 44 (2-3) (2004), 125-134.
[5]	W. Koster, (1991). “Effect of Residual Stress on Fatigue of Structural Alloys”, Proceedings of the Third International Conference, ASM International, Indianapolis, Indiana, USA, (1991), 19.
[6]	K.S.S. Lopes, W.F. Sales, and E.S. Palma, (2008) “Influence of machining parameters on fatigue endurance limit of AISI 4140 steel”, Journal of the Brazillian Society of Mechanical Science & Engineering, 30 (1) (2008), 77-83.
[7]	H. Sasahara, “The effect on fatigue life of residual stress and surface hardness resulting from different cutting conditions of 0.45%C steel”, International Journal of Machine Tools and Manufacture, 45 (2) (2005), 131-136.
[8]	D. Arola, and C.L. Williams, “Estimating the Fatigue Concentration Factor of Machined Surfaces”, International Journal of Fatigue, 24 (9), 923-930.
[9]	Q. Huang, and J.X. Ren, “Surface integrating and its effects on the fatigue life of the nickel-based superalloy GH33A”, International Journal of Fatigue, 13(14) (1991), 322-326
[10]	R. Balkrishna and C.S. Yung, “Analysis on high-speed face-milling of 7075-T aluminium using carbide and diamond cutters”, International Journal of Machine Tools & Manufacture, 41(2001),1763-1781.
[11]	H. Itoga, K.Tokaji, M. Nakajima, and H.H. Ko, “Effect of Surface Roughness on Step- Wise S-N Characteristic in High Strength Steel”, Int. J. of Fatigue, 25 (5) (2003), 379-385.
[12]	T. Mohammed, S. Montasser, and B. Joachim, “A Study of the Machining Parameters on the Surface Roughness in the End-Milling Process”, Jordan Journal of Mechanical and Industrial Engineering, 1(2007), 1-5.
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APA Style

Sunday J. Ojolo, Ifeoluwa J. Orisaleye, Nnaemeka Obiajulu. (2014). Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy. International Journal of Materials Science and Applications, 3(6), 391-398. https://doi.org/10.11648/j.ijmsa.20140306.27

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ACS Style

Sunday J. Ojolo; Ifeoluwa J. Orisaleye; Nnaemeka Obiajulu. Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy. Int. J. Mater. Sci. Appl. 2014, 3(6), 391-398. doi: 10.11648/j.ijmsa.20140306.27

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AMA Style

Sunday J. Ojolo, Ifeoluwa J. Orisaleye, Nnaemeka Obiajulu. Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy. Int J Mater Sci Appl. 2014;3(6):391-398. doi: 10.11648/j.ijmsa.20140306.27

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@article{10.11648/j.ijmsa.20140306.27,
  author = {Sunday J. Ojolo and Ifeoluwa J. Orisaleye and Nnaemeka Obiajulu},
  title = {Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy},
  journal = {International Journal of Materials Science and Applications},
  volume = {3},
  number = {6},
  pages = {391-398},
  doi = {10.11648/j.ijmsa.20140306.27},
  url = {https://doi.org/10.11648/j.ijmsa.20140306.27},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmsa.20140306.27},
  abstract = {Machining involves the thermal, elastic and plastic deformations of the surface layer which result in strain hardening, structural changes and development of residual stresses. These cause surface irregularities which may increase the risk of fatigue failure of material during usage. This study involves the investigation of the influence of cutting speed, feed rate and tool geometry on the fatigue life of end-milled specimens of 2024-aluminium alloy using a design of experiment approach. The experimental design constructed was such that the specimens were subjected to different machining conditions. Data analysis was carried out with Relia Soft OfficeTM 7 DOE++ software and Analysis of Variance (ANOVA). The study showed that by decreasing the feed rate (from 60mm/min to 7mm/min) and increasing the cutting speed (from 3.77m/min to 48.25m/min) significantly resulted in a higher fatigue life (from 1.93x103 cycles to 2.53x103 cycles). Whereas, the rake angle had the least significant effect on the fatigue life, it was discovered that the feed rate was found to be the most influential factor.},
 year = {2014}
}

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TY - JOUR
T1 - Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy
AU - Sunday J. Ojolo
AU - Ifeoluwa J. Orisaleye
AU - Nnaemeka Obiajulu
Y1 - 2014/12/08
PY - 2014
N1 - https://doi.org/10.11648/j.ijmsa.20140306.27
DO - 10.11648/j.ijmsa.20140306.27
T2 - International Journal of Materials Science and Applications
JF - International Journal of Materials Science and Applications
JO - International Journal of Materials Science and Applications
SP - 391
EP - 398
PB - Science Publishing Group
SN - 2327-2643
UR - https://doi.org/10.11648/j.ijmsa.20140306.27
AB - Machining involves the thermal, elastic and plastic deformations of the surface layer which result in strain hardening, structural changes and development of residual stresses. These cause surface irregularities which may increase the risk of fatigue failure of material during usage. This study involves the investigation of the influence of cutting speed, feed rate and tool geometry on the fatigue life of end-milled specimens of 2024-aluminium alloy using a design of experiment approach. The experimental design constructed was such that the specimens were subjected to different machining conditions. Data analysis was carried out with Relia Soft OfficeTM 7 DOE++ software and Analysis of Variance (ANOVA). The study showed that by decreasing the feed rate (from 60mm/min to 7mm/min) and increasing the cutting speed (from 3.77m/min to 48.25m/min) significantly resulted in a higher fatigue life (from 1.93x103 cycles to 2.53x103 cycles). Whereas, the rake angle had the least significant effect on the fatigue life, it was discovered that the feed rate was found to be the most influential factor.
VL - 3
IS - 6
ER -

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Author Information

Sunday J. Ojolo

Dept. of Mechanical Engineering, University of Lagos, Akoka-Yaba, Lagos, Nigeria
Ifeoluwa J. Orisaleye

Dept. of Mechanical Engineering, University of Lagos, Akoka-Yaba, Lagos, Nigeria
Nnaemeka Obiajulu

Dept. of Mechanical Engineering, University of Lagos, Akoka-Yaba, Lagos, Nigeria

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APA Style

Sunday J. Ojolo, Ifeoluwa J. Orisaleye, Nnaemeka Obiajulu. (2014). Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy. International Journal of Materials Science and Applications, 3(6), 391-398. https://doi.org/10.11648/j.ijmsa.20140306.27

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ACS Style

Sunday J. Ojolo; Ifeoluwa J. Orisaleye; Nnaemeka Obiajulu. Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy. Int. J. Mater. Sci. Appl. 2014, 3(6), 391-398. doi: 10.11648/j.ijmsa.20140306.27

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AMA Style

Sunday J. Ojolo, Ifeoluwa J. Orisaleye, Nnaemeka Obiajulu. Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy. Int J Mater Sci Appl. 2014;3(6):391-398. doi: 10.11648/j.ijmsa.20140306.27

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@article{10.11648/j.ijmsa.20140306.27,
  author = {Sunday J. Ojolo and Ifeoluwa J. Orisaleye and Nnaemeka Obiajulu},
  title = {Machining Variables Influence on the Fatigue Life of End-Milled Aluminium Alloy},
  journal = {International Journal of Materials Science and Applications},
  volume = {3},
  number = {6},
  pages = {391-398},
  doi = {10.11648/j.ijmsa.20140306.27},
  url = {https://doi.org/10.11648/j.ijmsa.20140306.27},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmsa.20140306.27},
  abstract = {Machining involves the thermal, elastic and plastic deformations of the surface layer which result in strain hardening, structural changes and development of residual stresses. These cause surface irregularities which may increase the risk of fatigue failure of material during usage. This study involves the investigation of the influence of cutting speed, feed rate and tool geometry on the fatigue life of end-milled specimens of 2024-aluminium alloy using a design of experiment approach. The experimental design constructed was such that the specimens were subjected to different machining conditions. Data analysis was carried out with Relia Soft OfficeTM 7 DOE++ software and Analysis of Variance (ANOVA). The study showed that by decreasing the feed rate (from 60mm/min to 7mm/min) and increasing the cutting speed (from 3.77m/min to 48.25m/min) significantly resulted in a higher fatigue life (from 1.93x103 cycles to 2.53x103 cycles). Whereas, the rake angle had the least significant effect on the fatigue life, it was discovered that the feed rate was found to be the most influential factor.},
 year = {2014}
}

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