现代飞机中大量使用了整体结构件以提高其飞行速度、机动性和可靠性等性能，但整体结构件尺寸大、材料去除率高、加工刚度差等特点也使得其加工变形难以预测和控制。工件残余应力场在切削过程中多种因素作用下的演变过程是引起加工变形的重要因素，论文即围绕切削残余应力的产生和演变机理及其对薄壁零件加工变形的影响开展研究。 论文对切削残余应力的本质和产生机理进行了多角度的探究和分析。切削残余应力主要源于切削过程中力、热载荷引入的非均布塑性变形，切削热载荷倾向于在表面引入残余拉应力，切削力载荷的机械效应倾向于在表面引入残余压应力。论文提出了新的切削表面残余应力经验预测模型，可以反映切削残余应力的产生机理并取得了较好的预测效果。分析了残余应力场的能量属性，从能量角度建立了切削参数、切削载荷和残余应力的关联。基于所提出的能量评价指标，可对残余应力整体分布进行评价和预测。 根据切削残余应力的产生机理，论文应用切削滑移线分析模型和移动热源温度场模型，分别建立了切削力载荷和温度分布的理论模型，然后基于热弹塑性加载理论，建立了切削残余应力的理论模型，可以较好地预测切削残余应力的分布规律。基于该理论模型，进一步归纳了影响切削残余应力的各类因素，并分析了切削力、热载荷影响残余应力数值和分布范围的规律。 论文分析了初始应力影响切削应力分布的规律，探索了典型的连续粗、精加工条件下切削残余应力场的演变规律。初始拉（或压）应力使得切削应力分布整体倾向于拉（或压）应力，但该切削应力分布并不等于初始应力和无初始应力时切削应力分布的叠加。论文在切削残余应力理论模型中进一步考虑了初始应力因素，建立了可以反映切削过程中工件内应力场演变机理的切削残余应力理论模型，并分析了不同数值、不同范围的初始应力对最终残余应力分布的影响。 最后，论文对零件加工过程中内应力场的演变机理进行了分析。根据粗、精加工影响工件内应力分布的特点，将有限元分析和理论求解相结合，提出了新的薄壁结构件加工变形预测方法。基于单元生死技术和论文建立的考虑初始应力场的残余应力理论模型，建立了相应的软件平台，并针对典型的航空薄壁结构件进行了应用验证。研究结果初步表明，切削表面层残余应力对薄壁结构件加工变形的影响不可忽视，考虑切削表面层残余应力分布，可提高对加工变形的预测精度。

Monolithic components made of large-scale workblanks are now widely used in aviation industry in order to improve the velocity, maneuverability and reliability of planes. The characteristics of monolithic components, such as large size, high material removal rate, thin-walled structure, and low machining stiffness, make it difficult to predict and control the machining distortion. The evolution process of residual stress field within the workpiece during the machining process is an important factor causing the machining distortion. And this dissertation is focused on the generation and evolution mechanism of machining-induced residual stress and its influence on the machining distortion of thin-walled components. This dissertation presents the analysis on the nature and generation mechanism of machining-induced residual stress through multiple approaches. The main source of machining-induced residual stress is the non-uniform plastic deformation introduced by the thermo-mechanical loads in cutting process. Based on the qualitative analysis that the thermal loads tend to introduce tensile surface residual stress while mechanical loads tend to introduce compressive surface residual stress, a new empirical prediction model of surface residual stress was proposed, which reflects the generation mechanism of machining-induced residual stress and achieved good prediction accuracy. The nature of the residual stress field was further analyzed through energy approach, which connects the machining parameters, machining loads and the residual stress. New evaluation criteria of residual stress field were defined, and they can be used to evaluate and predict the overall distribution state of the machining-induced residual stress. The slip-line cutting model and the moving heat source model were used to model the mechanical loads and the temperature distribution during machining process, and further the theoretical prediction of machining-induced residual stress was realized with thermo-elasto-plastic calculation. This theoretical model can be used to predict the distribution law of the machining-induced residual stress. The factors influencing machining-induced residual stress such as cutting parameters, tool parameters, and material properties were analyzed, and the effects of mechanical and thermal loads on the amplitude and distribution of machining-induced residual stress were studied. The influence of initial stress on the machining stress field was studied, and the evolution mechanism of machining-induced residual stress in successive cutting process was analyzed. Tensile or compressive initial stress makes the overall distribution of machining stress tend to be tensile or compressive, respectively. But the machining stress under the influence of initial stress is not the algebraic sum of the initial stress and the original machining stress without initial stress. A more comprehensive theoretical model considering the initial stress distribution was proposed, and the influence of initial stress field on machining-induced residual stress, or the evolution mechanism of the machining-induced residual stress, was further studied quantitatively. The evolution process of the inner stress field of thin-walled components during machining process was analyzed. And a new finite element prediction method of the machining distortion was established, considering the evolution of inner stress during roughing and finishing process. The software platform was built to realize the proposed method, which combines finite element analysis and theoretical calculation. The element birth and death technology, and the theoretical prediction model of machining-induced residual stress established in this dissertation considering the influence of initial stress, were utilized. The method was preliminarily tested for the deformation prediction of a typical thin-walled component, and the results indicated that the influence of machining-induced residual stress on the machining distortion of thin-walled structure should not be neglected, and the new prediction method achieved better accuracy.