Residual stress analysis of NiTi shape memory alloy in multi-step machining based on abaqus

This study employs a finite element model validated by residual stress experiments to investigate the influence of cutting speed and feed per tooth on NiTi shape memory alloy surface residual stress when two-step machining. The machining is performed under two methods through single-factor simulations: variable parameters in the first step with fixed parameters in the second step, and fixed parameters in the first step with variable parameters in the second step. The results indicate that the surface residual stress after the first cutting step is compressive and gradually decreases as cutting speed and feed per tooth increase. This results from the combined effects of mechanical stress induced by cutting force and thermal effects arising from cutting temperature. The residual compressive stress on the surface of the second step increases first and then decreases with the increase of cutting speed in the second step when the first step is machining with constant parameters, and the maximum value appears at v c2 = 200 m min −1 . This study offers critical theoretical support for developing a multi-step residual stress prediction model and guidance on optimizing machining processes.