In order to explore the influence law of milling parameters on residual stress induced in the process of milling ideal high-temperature structural material of gamma-TiAl alloy

the extreme difference analysis method is used based on orthogonal experiment data processing. The relationships between different levels of process factors and residual stress are established

as well as the thermal-mechanical mechanisms are analyzed. At the same time

a sensitivity mathematical model of machining factors to residual stress is obtained

which determines the parameters optimization range to get larger residual compressive stress. Research shows that during the range of experimental parameters

the residual stresses along the direction of stepper and feed are all compressive caused by cold plasticity deformation mainly. With regard to cutting parameter sensitivity analysis

it has been found that the residual stress is most sensitive to the milling speed

as one of design variables

while nearly the same degree to feed per tooth

cutting depth and cutting width

which provides a theoretical basis to control surface residual stress in the milling process of titanium aluminium alloy.