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<p>Five-axis machining-induced residual stress (MIRS) significantly affects part performance and precision. However, the tool attitude alters material removal, causing variable chip flow and velocity. This variability makes it difficult to use traditional turning or three-axis milling prediction methods for five-axis MIRS modeling. Thus, this paper proposes a theoretical method for modeling five-axis MIRS, considering the tool attitude. Firstly, the influence of tool attitude on-chip flow direction and velocity is analyzed. Then, the loading path is redefined based on the two-dimensional stress plane at the tool/part contact region, and the loading stress is modeled using variable cutting velocity. Finally, by combining loading stress and the loading path, the model of five-axis MIRS is established with the elastic–plastic method. Validation experiments in plane and curved surface milling show prediction errors of 12.4% and 14.1%, respectively. Results indicate that increasing the lead or tilt angle shifts surface MIRS towards tensile stress, while compressive stresses move closer to the workpiece surface. The method provides insights into the effect of tool attitudes on MIRS and lays the foundation for controlling machining quality in complex parts.</p>

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Theoretical modeling method of five-axis machining-induced residual stress considering tool attitude

  • 期刊论文

  • 发表日期：

    2025年8月28日

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  • Changjiu Xia,
  • Yuanyang Wang,
  • Zehua Wang

摘要

Five-axis machining-induced residual stress (MIRS) significantly affects part performance and precision. However, the tool attitude alters material removal, causing variable chip flow and velocity. This variability makes it difficult to use traditional turning or three-axis milling prediction methods for five-axis MIRS modeling. Thus, this paper proposes a theoretical method for modeling five-axis MIRS, considering the tool attitude. Firstly, the influence of tool attitude on-chip flow direction and velocity is analyzed. Then, the loading path is redefined based on the two-dimensional stress plane at the tool/part contact region, and the loading stress is modeled using variable cutting velocity. Finally, by combining loading stress and the loading path, the model of five-axis MIRS is established with the elastic–plastic method. Validation experiments in plane and curved surface milling show prediction errors of 12.4% and 14.1%, respectively. Results indicate that increasing the lead or tilt angle shifts surface MIRS towards tensile stress, while compressive stresses move closer to the workpiece surface. The method provides insights into the effect of tool attitudes on MIRS and lays the foundation for controlling machining quality in complex parts.