With the aerospace and aviation industry development, machining deformation is the most prominent and urgent problem in the production process. Studies have shown that initial residual stress (RS) is the main factor causing the deformation of this type of part. Since residual stresses must be analyzed quantitatively, a series of measurement methods have been developed for this purpose. Remarkably, a series of measurement technologies inevitably need to include the corresponding calibration process, which is the fundamental element to ensure RS measurement accuracy. In this investigation, we developed a non-contact stress calibration method based on deflection value to study the measurement deviation of forging residual stress in the aerospace field. The constant stress beam (CSB) mechanical and finite element models of Ti6Al4V titanium alloy were established. The deflection measurement method was implemented using the visual system based on pattern speckle technology. A high precision loading device was developed to provide an accurate external load for CSB. A novel calibration technology based on the deflection method was proposed to realize RS measurement’s calibration process. We have successfully applied the CSB bending test campaigns and deflection metrology method to calibrate the stress values measured by the Static strain measuring instrument of Sigma and the Stress measuring instrument of Proto-ixrd. The results of theoretical and simulation stress are highly consistent with the calibration experiment. Calibration experiments combining the pattern speckle technology and the deflection method allow the stress measurement process’s calibration according to the correction factor. The research provides a great impetus to the development of precise quantitative measurement of RS.

随着航空航天工业的发展，机械变形是生产过程中最突出，最紧迫的问题。研究表明，初始残余应力（RS）是导致此类零件变形的主要因素。由于必须对残余应力进行定量分析，为此已开发了一系列测量方法。值得注意的是，一系列测量技术不可避免地需要包括相应的校准过程，这是确保RS测量精度的基本要素。在这项研究中，我们开发了一种基于挠度值的非接触应力校准方法，以研究航空航天领域锻造残余应力的测量偏差。建立了Ti6Al4V钛合金的恒应力梁（CSB）力学和有限元模型。使用基于图案斑点技术的视觉系统来实现挠度测量方法。开发了一种高精度的加载设备，可为CSB提供准确的外部负载。提出了一种基于偏转法的新型标定技术，以实现RS测量的标定过程。我们已经成功地应用了CSB弯曲测试活动和挠度度量方法来校准由Sigma的静态应变测量仪和Proto-ixrd的应力测量仪测得的应力值。理论应力和模拟应力的结果与校准实验高度一致。结合图案斑点技术和偏转方法的校准实验可以根据校正因子对应力测量过程进行校准。该研究为RS的精确定量测量的发展提供了强大的动力。