A research program is developed for the study of residual stresses in machining. It is well known that surface residual stresses develop as a result of many machining processes. This leads to a considerable reduction in fatigue life. It is therefore critical to have a reliable prediction of surface stresses as a function of process parameters and tool geometry.

In this body of work a methodology is utilized that accounts for thermal and mechanical stresses. Combined with an appropriate flow rule and a final relaxation procedure, the technique is demonstrated to provide accurate predictions of residual stresses.