| Citation: | ZHOU Huimin, LIU Zonghui, LI Ruifeng, et al. Effect of milling process on surface residual stress of titanium alloy disk[J]. Journal of Aerospace Power, 2026, 41（5）：20250203 doi: 10.13224/j.cnki.jasp.20250203
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The surface residual stress induced by milling, which is the final machining process for aero-engine disks, is an important input for the safety design of aero-engine disks. The three-dimensional milling simulation is time-consuming because of geometry generation and remeshing, and the two-dimensional milling simulation oversimplifies variables of milling. To overcome the limitations of the three-dimensional and two-dimensional milling simulation, a two-dimensional continuous milling simulation model considering the helix angle was proposed. With reference to the actual milling process, deviations from the milling parameters were introduced, and the influence of spindle speeds and feed rates on residual stress was analyzed. The results showed that the surface residual stress induced by the milling process was compressive stress, with a magnitude of −20— −50 MPa, and the residual stress depth ranged from 0—100 μm. With the increase of the spindle speed, the surface residual compressive stress showed a decreasing trend, while the spindle speed had a minor effect on the residual stress depth. As the feed rate increased, the absolute value of the surface residual stress increased.
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