FEM analysis of mechanical state on sequentially machined surfaces

A thermo-elastic-viscoplastic explicit FEM model has been developed to predict effects of sequential orthogonal cuts on the mechanical state and cutting mechanisms in a machined layer. Residual stress distribution is shown to be significantly changed and cutting mechanisms slightly changed in sequential cuts. A method to compressively pre-stress a sequentially machined surface was proposed by planning the uncut chip thickness. Effects of unloading of cutting forces, cutting temperatures, and clamping forces on the residual stress distribution were evaluated.