Simulating the effects of machining induced residual stress on geometric variation

Paper in proceeding, 2026

Most metallic components undergo machining to some extent during manufacturing. It is a very complex process where extreme temperatures and forces are generated on the surface, primarily due to friction. These conditions often give rise to significant residual stress on the surface of the finished product, which may be sufficient to alter both the behavior of the material and the geometry of the product. The geometric effects of these stresses are further complicated by the presence of residual stresses from previous processes, such as casting or additive manufacturing (AM). A methodology for applying machining-induced residual stress onto a geometry to estimate the geometric distortion that can be expected from a machining process in an AM context is proposed. This study compares a range of feasible residual stress magnitudes to demonstrate the importance of tailoring the process parameters to minimize the effects of machining induced residual stress on the geometric variation.