Inverse analysis of machining residual stress based on hybrid model

Machining-induced residual stress significantly impacts the fatigue life and service performance of machined components. Appropriate compressive residual stress can enhance resistance to crack initiation, while tensile residual stress may be detrimental. In this study, an inverse analysis is conducted to optimize the cutting parameters for achieving desired residual stresses. The analysis begins by predicting the machining-induced thermal-mechanical loads in the primary shear zones using analytical methods. Subsequently, an Arbitrary Lagrangian-Eulerian (ALE) based numerical model is proposed to calculate the resulting residual stresses by incorporating the determined thermal-mechanical loads. This analytical-numerical hybrid method facilitates rapid and accurate modeling of residual stresses. Then, the Newton’s method is employed to deduce cutting parameters iteratively, ensuring a proper residual stress. Finally, the results of inverse analysis are compared with experimental measurements to validate its efficacy.