Machining residual stress model with shear zones defined as Eulerian boundaries

The increasing demand for the optimisation and control of machining-induced residual stress necessitates an efficient and accurate method for predicting the cutting residual stress. To address this, we propose a novel hybrid model based on the Arbitrary Lagrangian-Eulerian technique. The model simulates cutting-induced residual stress in both two-dimensional and three-dimensional conditions. It treats the primary and tertiary shear zones as Eulerian boundaries, allowing the application of thermos-mechanical loads in these regions and enabling the simulation of material removal without modelling chip formation. This reduces simulation time by over 90 %. The final residual stress is computed from the subsurface plastic strain using eigenstrain theory, thereby eliminating the need to simulate the release or cooling process. Experimental measurements are also incorporated to determine the equivalent thermo-mechanical loadings, further improving model accuracy. By comparing this novel hybrid method with traditional numerical models and experimental data, we demonstrate its superiority in terms of efficiency and accuracy. Notably, uncut chip thickness has little effect on cutting-edge squeezing. Instead, it primarily influences residual stress through changes in primary shear zone loading.