Articles | Volume 16, issue 2
https://doi.org/10.5194/ms-16-457-2025
https://doi.org/10.5194/ms-16-457-2025
Research article
 | 
15 Sep 2025
Research article |  | 15 Sep 2025

Effect analysis of residual stress on the machined surface of a titanium alloy (TC4) based on parameter optimization of a finite-element model

Chenyu Wang, Changyou Li, Zhi Tan, Huihui Miao, Wei Sun, and Jinquan Li

Cited articles

Chen, G., Caudill, J., Chen, S., and Jawahir, I. S.: Machining-induced surface integrity in titanium alloy Ti-6Al-4V: An investigation of cutting edge radius and cooling/lubricating strategies, J. Manuf. Process., 74, 353–364, https://doi.org/10.1016/j.jmapro.2021.12.016, 2022. 
Hassaan, A. M. and Han, Y. S.: A Finite Element Analysis on the Effect of Scanning Pattern and Energy on Residual Stress and Deformation in Wire Arc Additive Manufacturing of EH36 Steel, Materials (Basel, Switzerland), 16, https://doi.org/10.3390/MA16134698, 2023. 
Hou, M., Mou, W., Yan, G., Song, G., Wu, Y., Ji, W., Jiang, Z., Wang, W., Qian, C., and Cai, Z.: Effects of Different Distribution of Residual Stresses in the Depth Direction on Cutting Performance of TiAlN Coated WC-10wt%Co Tools in Milling Ti-6Al-4V, Surface and Coatings Technology, 397, 125972, https://doi.org/10.1016/j.surfcoat.2020.125972, 2020. 
Ju, K., Duan, C., Sun, Y., Shi. J., Kong, J., and Abdolhamid, A.: Prediction of machining deformation induced by turning residual stress in thin circular parts using ritz method, Journal of Materials Processing Tech., 307, https://doi.org/10.1016/J.JMATPROTEC.2022.117664, 2022. 
Kuo, C., Chen, C., Jiang, S., and Chen, Y.: Effects of the Tool Geometry, Cutting and Ultrasonic Vibration Parameters on the Cutting Forces, Tool Wear, Machined Surface Integrity and Subsurface Damages in Routing of Glass-Fibre-Reinforced Honeycomb Cores, J. Manuf. Process., 104, 59–75, https://doi.org/10.1016/j.jmapro.2023.08.051, 2023. 
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Short summary
In this paper, data-driven and genetic algorithms are combined to optimize the parameters of the Jonson–Cook model and improve the simulation accuracy. Experiments verify the accuracy of the model, and the influence of cutting data on the residual stress of the machined surface is discussed, which provides suggestions for the cutting process and tool design.
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