Residual stress (RS) has significant impact on cutting process optimization. However, conventional process modeling approaches are limited to only single cutting pass on very short length and time scales due to the exceedingly high computational cost. This work provides a new concept of equivalent loading which enables an efficient modeling approach to predict RS in an actual machined surface by incorporating multiple cutting passes and crossing different length and time scales. The predicted residual stress profiles are validated in turning Inconel 718 superalloy under different edge geometries and process conditions.

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