In machining practice, repeated passes result in the presentation of pre-strained material to the cutting edge. The effect of such strains on machining forces and chip geometry is investigated in a series of machining experiments performed on α-brass using a variety of cutting conditions. It is found that both thrust force and chip side spread depend on surface preparation, but cutting force and chip length ratio are not significantly affected by surface preparation under the conditions of the experiments. Surface preparation is also found to affect the scatter of results.
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