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Yayın Investigation of residual stresses induced by milling of compacted graphite iron by x-ray diffraction technique(Springer, 2024-04) Kara, Mehmet Emre; Kuzu, Ali Taner; Bakkal, MustafaThis study investigates the relationship between residual stresses, cutting parameters, and machining performance in the milling process of compacted graphite iron (CGI). X-ray diffraction (XRD) analysis is employed to measure residual stresses on the cast and milled surfaces, while cutting force modeling is utilized to calculate the tangential force, power, and active work. The results demonstrate that tensile residual stresses are predominant on the milled surfaces, attributed to the both mechanical and thermal loads generated during milling. By analyzing various cutting conditions, it is observed that lower feeds contribute to reduced plastic deformation, resulting in lower residual stress levels. Additionally, higher cutting speeds lead to higher temperatures, but due to the shorter machining time, heat accumulation is limited, resulting in higher residual stresses, especially at low feeds. At high feeds, residual stresses decreased as the cutting speed increased. The interplay between cutting parameters and residual stresses highlights the need for optimizing cutting conditions to enhance fatigue strength in CGI components. These findings provide valuable insights for process optimization and quality control in the milling of CGI materials.Yayın Predictive modelling of surface roughness and residual stress induced by milling of hot forged and heat treated AA7075(Springer Nature, 2025-11-03) Tok, Görkem; Dinçer, Ammar Tarık; Kuzu, Ali Taner; Bakkal, MustafaThis study investigates the influence of cutting parameters on residual stress and surface roughness during the milling of hot-forged and T6 heat-treated AA7075 components. Using Taguchi L9 and full-factorial experimental designs and regression modelling, the research highlights important relationships between cutting parameters (cutting speed, feed rate, and depth of cut), residual stress and surface roughness. Higher cutting speeds (350 m/min) and lower feed rates (0.1 mm/tooth) significantly minimized residual stresses, with hoop stress values decreasing from 108.7 MPa at lower speeds (150 m/min) to approximately 73.4 MPa at higher speeds, and axial stress values ranging from 45.9 MPa to 88.5 MPa. Surface roughness (Ra) was most influenced by feed rate, with measurement values varying between 0.25 mu m and 0.92 mu m. Support Vector Regression (SVR) demonstrated better accuracy for predicting residual stress (MAPE: 11.5%) and surface roughness (MAPE: 7%), outperforming Lasso and Ridge regression models. These findings provide a consistent framework for optimizing cutting parameters and enhancing residual stress and surface roughness in AA7075 machining processes, offering practical implications for improving component performance and manufacturing efficiency.
