Prediction of Micro-Milling-Induced Residual Stress and Deformation in Titanium Alloy Thin-Walled Components and Multi-Objective Collaborative Optimization

The intrinsically low stiffness of titanium alloy thin-walled components causes residual stresses to readily accumulate during high-speed micro-milling, leading to deformation and hindering machining precision. To clarify the residual-stress formation mechanism and enable deformation control, this study first proposes a surface residual stress characterization model based on an exponentially decaying sinusoidal function, with model parameters efficiently identified via an improved particle swarm optimization algorithm, allowing rapid characterization of stress distributions under different process conditions. A response surface model constructed using a central composite design is then employed to reveal the coupled effects of machining parameters on residual stress and top-surface deformation. On this basis, a GA-BP neural network-based prediction framework is developed to improve the accuracy of residual stress and deformation prediction, while the AGE-MOEA2 multi-objective evolutionary algorithm is used to optimize micro-milling parameters for the simultaneous minimization of residual stress and deformation via Pareto-optimal solutions. Validation experiments on thin-wall micro-milling confirm that the optimized parameters significantly reduce peak residual stress and suppress top-surface deformation. The proposed modeling and optimization strategy provides an effective reference for high-precision machining of titanium alloy thin-walled components.