residual stress analysis in milled din 1.2344 die casting mold: a fusion of numerical simulation and xrd experimental validation

Milling is one of the most widely used processes in the manufacturing of die-casting molds and other industrial molds. a major challenge in this process is the generation of residual stresses on the workpiece surface, which can lead to distortions and compromise the precision and performance of the mold. this study investigates the residual stresses induced by milling din 1.2344 steel, utilizing the taguchi design of experiments (l9 array) and validating the results experimentally through x-ray diffraction (xrd) tests. the study examines the effects of three primary milling parameters, cutting speed, feed rate, and depth of cut, on residual stresses and identifies the optimal conditions for minimizing these stresses. the results indicate that increasing the cutting speed from 50 to 112.5 m/min reduces tensile residual stresses by 22%. additionally, increasing the feed rate from 10 to 20 mm/s leads to an 18% reduction in residual stresses; however, further increases beyond this threshold lead to stress amplification. regarding the depth of cut, increasing it from 0.2 to 0.4 mm causes a 15% rise in residual stresses, while a depth of 0.6 mm results in a 10% reduction. furthermore, the cutting forces fx and fz initially increase moderately with cutting speed but decrease at 112.5 m/min, attributed to thermal softening effects. these findings offer valuable insights for optimizing the milling process and improving the quality of machined components in the mold-making industry.