Effects of Sequential Cuts on Residual Stresses when Orthogonal Cutting Steel AISI 1045

AbstractResidual stresses (RS) play a critical role in controlling part performance. Even though their final statemay not only depend on the final finishing path, a few articles could be found on the effects of sequential cuts on RS. The current study focuses on modelling the effects of sequential cuts on RS,using finite element modelling,whendry orthogonal cuttingAISI 1045. Different process parameters (cutting forces, temperatures, stresses, shear angle and plastic strain) were also examined, in order to explain the RS findings. For model validation, orthogonal cutting tests were performed on a CNC lathe, andsurface RSwere measured using XRD