Abstract: To address the issue of part deformation caused by uneven residual stresses resulting from cumulative tool wear during milling of thin-walled aerospace casings, a residual stress-deformation prediction model that accounts for tool wear evolution was established. By comparing the zone-independent cutting method with the circumferential continuous cutting method, a layered variable-feed optimization method was proposed that combines the global reference stress center and the layer stress center, with feed parameters and wear trajectories updated alternately. Simulation results show that, compared with zone-independent cutting, circumferential continuous cutting reduces the maximum radial deformation by more than 40% and the maximum axial deformation by approximately 17.4%. After variable-feed optimization, these values are further reduced by 8.9% and 5.1%, respectively. Comparative tests on two simulated high-temperature alloy casing specimens showed that the maximum absolute deformations of the optimized specimen at cross-sections 30, 80, and 130 mm from the reference end face were reduced by 43.0%, 49.6%, and 55.0%, respectively, compared with those of the reference specimen. The results indicate that coordinated optimization of the cutting sequence and feed parameters can improve residual stress uniformity and suppress deformation during casing machining.