Abstract
In order to achieve the desired surface integrity in a workpiece, it is important to select the correct cutting variables and the tool geometry. The influence of these measures on residual stresses induced in machining Aluminum Magnesium alloy (Al-3Mg) is investigated. Four input parameters are considered: cutting speed, feed rate, depth of cut and nose radius. The Response Surface Method was used to minimize the number of experiments to be conducted. Residual stresses were measured by electrochemical analysis by removing very fine layers of the machined surface. Experiments have shown that the residual stresses on the machined surface were often of the compressive type which tend to delay crack initiation and propagation that often tends to start from the machined surface itself.