Modeling of residual stresses in milling

A model to predict residual stresses produced from milling is presented. It uses process conditions as inputs and predicts surface and subsurface residual stress profiles due to milling. The model formulation incorporates cutting force and cutting temperature predictions and utilizes those parameters to define the thermomechanical loading experienced by the workpiece. Model predictions are compared with published experimental data for both cutting forces and residual stress profiles. The results show that the model performs well in predicting residual stress trends for various milling conditions. Residual stress magnitudes as well as profiles are well predicted with the modeling approach.