Elastic stress release is mostly considered during material removal while measuring in-depth residual stresses inside a structure. It can give rise to large measurement errors in the case of high residual stress where plasticity effect is involved. This paper focuses on analysis of elastic-plastic stress release due to material removal and the induced error in measurement of residual stress. Simulation of electropolishing prepared for XRD analysis and contour method process is performed on a shot peened 316L cylindrical specimen by accounting for the work hardening effect. Results show that elastic-plastic stress release can occur in iterative electropolishing when the initial yielding relation is broken. However, the induced error is acceptable with a maximum error of 1.67%. In comparison, significant release of residual stress after cutting in contour method activates obvious plastic flow, and induces a much larger deviation of the measured axial residual stress. Influence of the initial work hardening is discussed by analysing the plastic flow mechanism in the two material removals. It is concluded that occurrence and the influence extent of plastic flow rely on the stress release amount and the initial state of yielding relation which is defined by residual stress, work hardening, and material behaviour.

在去除材料时，通常会考虑弹性应力的释放，同时测量结构内部的深度残余应力。在涉及塑性效应的高残余应力的情况下，会引起较大的测量误差。本文着重分析由于材料去除引起的弹塑性应力释放以及残余应力测量中的诱发误差。考虑到加工硬化效果，对喷丸的316L圆柱形试样进行了XRD分析和轮廓法过程准备的电抛光仿真。结果表明，当初始屈服关系被破坏时，在迭代电抛光中会发生弹塑性应力释放。但是，诱发误差是可以接受的，最大误差为1.67％。相比下，轮廓法切削后残余应力的显着释放会激活明显的塑性流动，并导致测得的轴向残余应力有更大的偏差。通过分析两种材料去除过程中的塑性流动机理，讨论了初始工作硬化的影响。得出的结论是，塑性流动的发生和影响程度取决于应力释放量和屈服关系的初始状态，屈服关系的初始状态由残余应力，加工硬化和材料性能决定。