Effect of Machining Cusps on the Stress Concentration Factor on Curved Surface

General Information

ISSN: 2278-0149 (Online)
Short Title: Int. J. Mech. Eng. Robot. Res.
Frequency: Bimonthly
DOI: 10.18178/ijmerr
Managing Editor: Ms. Jennifer Zeng
Abstracting/Indexing: ESCI (Web of Science), Scopus, CNKI, Google Scholar, Crossref, etc.
E-mail questions to IJMERR Editorial Office.
Acceptance Rate: 25%
APC: 1000 USD
Average Days to Accept: 78 days
Journal Metrics:

2.8

2023CiteScore

50th percentile

Article Metrics in Dimensions

Editor-in-Chief

Prof Richard (Chunhui) Yang

Professor of School of Engineering, Design and Built Environment, Western Sydney University, Australia. His research interests cover Industry 4.0, Additive Manufacturing, Advanced Engineering Materials and Structures (Metals and Composites), Multi-scale Modelling of Materials and Structures, Metal Forming and Metal Surface Treatment.

What's New

2024-12-18

Volume 13, No. 6 has been published online.

2024-10-25

All papers published in Vol. 13, No. 3&No. 4 have been indexed by SCOPUS.

2024-10-25

Volume 13, No. 5 has been published online.

Home > Articles > All Issues > 2018 > Volume 7, No. 5, September 2018 >

Md Shams E Tabriz and Simon Barrans

University of Huddersfield, Huddersfield, United Kingdom

Abstract—Recently multi-axis machining technology has improved significantly. It has become a widely accepted method of manufacturing components with complex, free form surfaces. Solid billet materials with negligible internal defects are used in this process. This provides increased durability and fatigue life over equivalent cast components. However, multi-axis machining using ball nose cutting tools leaves cusps as machining marks. The combination of tool size and step-over generates cusps with different depths and widths. Even though the cusps add extra material on top of the nominal surface, Finite Element Analysis (FEA) shows the maximum stress generated within the cusps is greater than that predicted from the cusp-free geometry. These stress concentrations generated by cusps can reduce the fatigue life and durability of a machined component.

This paper reports FEA results; simulating the effect of cusps on surfaces with a range of curvatures for a fixed tool size and six different cusps depth. The FEA results show that the stress concentrations due to surface curvature and cusps can be determined independently and then multiplied together to give the combined stress concentration factor. The results of this analysis will allow designers to specify a maximum machining cusp depth on a curved surface.

Index Terms—Multi-axis machining, cusps, machining marks, finite element analysis, stress concentration, surface curvature

Cite: Md Shams E Tabriz and Simon Barrans, "Effect of Machining Cusps on the Stress Concentration Factor on Curved Surface," International Journal of Mechanical Engineering and Robotics Research, Vol. 7, No. 5, pp. 552-557, September 2018. DOI: 10.18178/ijmerr.7.5.552-557