This research aims to elucidate the impact of sequential cutting on residual stress generation within orthogonal cutting processes, utilizing a combination of experimental trials and finite element method (FEM) simulations. A primary focus of this investigation is to determine how varying the depth of cut —specifically in relation to the affected layer generated during preceding operations— affects the final mechanical state of the workpiece. The results demonstrate that while chip thickness and shear angle exhibit initial variations, these parameters tend to stabilize as the total number of sequential cutting passes increases. Consequently, the distribution of residual stress within the surface layer of the machined workpiece converges toward a consistent steady state. Furthermore, the study provides specific insights into how the depth of cut interacts with a pre-existing affected layer. It was observed that when sequential cutting is performed at a depth sufficient to entirely remove the prior affected layer, the equivalent plastic strain reaches a converged and stable profile. Conversely, if the depth of cut only penetrates the middle portion of the affected layer, high plastic deformation zone near the surface is removed, resulting in a progressive relaxation or reduction of equivalent plastic strain. These findings highlight that the final residual stress state on a machined surface can be effectively managed—either to induce stable stress formation or to facilitate stress relaxation—by strategically adjusting the depth of cut relative to the affected layer produced in prior machining stages.
HIRAMA et al. (Thu,) studied this question.