The effect of residual stresses on the fatigue behavior as well as the dimensional stability of high precision part is very important. Machining operation consists generally multi-step operations from roughing to finishing. It is therefore critical to predict residual stresses under such configuration. In this paper, an analytical algorithm is proposed to predict the final residual stresses induced by a multi-step machining operation capturing the change of stress state of the workpiece as well as material hardening behavior during the multi-step orthogonal cutting. The model predictions were compared to other work’s finite element method (FEM) predictions.

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