Previous studies on machining-induced residual stress mainly concentrated on qualitative analyses of mechanical load and thermal load. Nevertheless, it remains a major challenge to quantify the influence of cutting force and heat on residual stress generation due to the lack of superposition mechanism. A newly empirical model of milling residual stress superposition was constructed to distinguish the effect of milling force from the effect of milling heat. The influence proportions of milling force and heat on the residual stress generation have been determined. Firstly, the residual stresses induced by the milling force, heat and force-heat coupling load were simulated independently, and the simulation models were verified by experiments. The simulation results presented that the milling force caused both residual compressive stress and residual tensile stress on the machined surface, while milling heat induced mainly residual tensile stress. Then, a mathematical model was put forward to quantify the superposition relationship between the force-induced residual stress and the heat-induced residual stress presented in the simulations. It has been found that the influence of milling force accounts for 53% to 78% in the generation of the surface residual stress when the force-to-heat ratio (R_FT) varies from 0.09 to 0.39. Finally, with a constant material removal rate, the conclusion can be drawn that the parameter combination with a higher force-to-heat ratio is more beneficial for the generation of residual compressive stresses on the machined surface, which has been confirmed by the case experiments. Therefore, quantitative analysis of residual stress generation and superposition turns to be possible by using the proposed modeling.

以往对加工引起的残余应力的研究主要集中在机械载荷和热载荷的定性分析上。然而，由于缺乏叠加机制，量化切削力和热量对残余应力产生的影响仍然是一个重大挑战。构建了铣削残余应力叠加的新经验模型，以区分铣削力的影响和铣削热的影响。确定了铣削力和热量对残余应力产生的影响比例。首先，分别对铣削力、热和力-热耦合载荷引起的残余应力进行了仿真，并通过实验验证了仿真模型。仿真结果表明，铣削力在加工表面同时引起残余压应力和残余拉应力，而铣削热主要引起残余拉应力。然后，提出了一个数学模型来量化模拟中出现的力致残余应力和热致残余应力之间的叠加关系。研究发现，当力热比(R_FT ) 从 0.09 到 0.39 不等。最后，在材料去除率恒定的情况下，可以得出结论，具有较高力热比的参数组合更有利于加工表面产生残余压应力，这已被案例实验所证实。 . 因此，通过使用所提出的模型，可以对残余应力的产生和叠加进行定量分析。