Machining-induced residual stresses in a part can significantly influence its performance and service time. It is common that the final surface of the part is produced after multiple cuts in the machining process. In multiple cuts, the previous cuts could often generate accumulated strain/stress and temperature on the part surface. These accumulated strain/stress and temperature will be brought to the subsequent cut or final cut and continuously affect the cutting forces, process temperatures, deformation zones, etc. in subsequent cut, and eventually affect the final residual stresses on the part. This paper reports on a joint experimental and numerical investigation to explore the influence of previous cuts on surface residual stresses with consideration of cutting parameters, cutting procedure, and tool geometries in multiple cut of Inconel 718 alloy. Coupled Eulerian and Lagrangian (CEL) formulation is used in a two/three-cuts numerical model. The loading cycles of the selected material nodes are characterised based on isotropic constitutive model (Johnson-Cook model) to analyse the underlying mechanism of residual stress evolution during cutting sequences. The results show that accumulated stress/strain induced by previous cuts lead to a more curled chip morphology, a slight decrease in cutting force and a slight increase in feed force in the subsequent cut. An increased magnitude and depth of compressive residual stresses in the finished workpiece are generated owing to the influence of previous cuts, and this is more obvious when the previous cut is implemented at a larger uncut chip thickness, using a more negative rake angle or a larger edge radius tool. The residual stress level might be controlled by optimizing the previous cuts to get the desired surface integrity.

零件中加工引起的残余应力会显着影响其性能和使用时间。零件的最终表面通常是在加工过程中经过多次切割后产生的。在多次切割中，先前的切割通常会在零件表面产生累积应变/应力和温度。这些累积的应变/应力和温度将被带到后续的切割或最终切割中，并不断影响后续切割中的切削力、工艺温度、变形区等，最终影响零件的最终残余应力。本文报告了一项联合实验和数值研究，以探讨先前切割对表面残余应力的影响，同时考虑切割参数、切割程序、和 Inconel 718 合金多次切削的刀具几何形状。耦合欧拉和拉格朗日 (CEL) 公式用于二/三切割数值模型。所选材料节点的加载循环基于各向同性本构模型（Johnson-Cook 模型）进行表征，以分析切削过程中残余应力演变的潜在机制。结果表明，先前切削引起的累积应力/应变导致切屑形态更加卷曲，切削力略有下降，而后续切削中的进给力略有增加。由于先前切削的影响，在成品工件中产生的压缩残余应力的幅度和深度增加，并且当以较大的未切削切屑厚度进行先前切削时，这一点更为明显，使用更负的前角或更大的边缘半径刀具。可以通过优化先前的切割来控制残余应力水平，以获得所需的表面完整性。