Residual stress has become more important than ever with the increasing performance requirement of components especially for those applied in safety-critical areas. As the machining process is fundamentally correlated with the acquired component properties, it is essential to fully understand the formation mechanism of residual stresses in the cutting process and its influence on the performance of the component. This paper presents results based on numerical and experimental analysis on the effect of tool geometry on thermal-mechanical load and residual stresses in orthogonal machining Inconel718 alloy. The Coupled Eulerian-Lagrangian (CEL) method is used to simulate the effect of tool geometry on temperatures, forces, equivalent plastic strains, and residual stresses. The local normal/tangential stress is introduced to determine the degree of the tensile plastic deformation induced by the tool. It is observed that a negative rake angle and a sharp edge radius tool tend to generate more compressive stress on the machined surface than the ones generated with positive rake angle tools and/or lager edge radius. Besides, an increase in flank wear produces less magnitude of compressive stress in subsurface due to a decreased local normal stress caused by increased flank contact length.

随着组件性能要求的不断提高，尤其是对于安全性至关重要的领域中的组件，残余应力已变得比以往更加重要。由于加工过程从根本上与所获得的零件特性相关，因此必须充分了解切削过程中残余应力的形成机理及其对零件性能的影响。本文基于数值和实验分析结果，介绍了刀具几何形状对正交加工Inconel718合金中热机械载荷和残余应力的影响。欧拉-拉格朗日耦合（CEL）方法用于模拟刀具几何形状对温度，力，等效塑性应变和残余应力的影响。引入局部法向/切向应力以确定工具引起的拉伸塑性变形的程度。可以看出，与使用正前角工具和/或较大的刃口半径所产生的应力相比，负前角和锐利的刃口半径工具趋于在加工表面上产生更大的压缩应力。此外，由于侧面接触长度的增加而引起的局部法向应力的减小，侧面磨损的增加在地下​​产生了较小的压缩应力。