Residual stresses have been considered to be an important parameter when friction stir processing (FSP) tool is to be manufactured. FSP has often been used for surface modification and fabrication of surface composites. Involuntary residual stress in a designed tool may cause it to fail before due time. Because of this, the knowledge about the stresses on the tool probe after its machining has been considered to be desirable. The present research has focused on the analysis of the residual stresses on the tip and periphery of the FSP tool probe which has been manufactured using H13 tool steel material during the turning processes on a CNC lathe machine. The experiments have been performed on two different types of tool probes, namely circular, tapered circular probes. ABAQUS/CAE simulation has been performed for circular and tapered circular probe, as the provision of a sustainable, simple and reasonable model to analyze the machining processes (using ABAQUS/CAE software) has been the primary objective of this research. The results have been found to be within a close range of the experimental observations. The same model can thus be applied to other geometries.

中文翻译：

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搅拌摩擦加工工具制造中残余应力测量的实验和仿真验证

在制造搅拌摩擦加工（FSP）工具时，残余应力已被视为重要参数。FSP经常被用于表面改性和表面复合材料的制造。设计工具中的非自愿残余应力可能导致其在适当时间之前失效。因此，关于工具探针在其加工之后的应力的知识被认为是合乎需要的。目前的研究集中在分析FSP工具探针的尖端和周边上的残余应力，该探针是在CNC车床的车削过程中使用H13工具钢材料制成的。实验是在两种不同类型的工具探针上进行的，即圆形，锥形圆形探针。ABAQUS / CAE仿真已针对圆形和锥形圆形探头进行，由于提供可持续，简单而合理的模型来分析加工过程（使用ABAQUS / CAE软件）一直是这项研究的主要目标。已经发现结果在实验观察结果的近范围内。因此，相同的模型可以应用于其他几何形状。