Abstract
We have developed a new tool that is called as the cutting-burnishing combined tool. This tool can generate effective compressive residual stress within the machined surface concurrently with the milling process. It expected to improve mechanical properties such as the fatigue life and the resistance to stress corrosion cracking. The developed tool has two inserts for cutting and two pins for burnishing. These pins are located just inside of the outer diameter of the tool. The pins are held by coned disk springs, and they rubs over the machined surface by the cutting edges. This paper presents the effect of the cutting conditions of the developed tool upon surface roughness, surface hardness and residual stress of aluminum alloy. Then we discuss the controllability of such mechanical properties of the machined surface with the setting of the machining conditions. As a result, the feed per tooth and the cross feed width was most important parameters affecting the compressive residual stress on the machined surface . Especially, as the feed per tooth is increased, compressive residual stress on the machined surface is decreased. Therefore, these conditions can controls compressive residual stress on the machined surface.
