The residual stress inside stock materials is a fundamental property related to the quality of manufactured parts in terms of geometric/dimensional stability and fatigue life. For large parts that must meet high-precision requirements, accurately measuring and predicting the residual stress field has been a major challenge. Existing technologies for measuring the residual stress field are either strain-based measurement methods or non-destructive methods with low efficiency and accuracy. This paper reports a new non-destructive method for inferencing the residual stress field based on deformation forces. In the proposed method, the residual stress field of a workpiece is inferred based on the characteristics of the deformation forces that reflect the overall effect of the unbalanced residual stress field after material removal operations. The relationship between deformation forces and the residual stress field is modeled based on the principle of virtual work, and the residual stress field inference problem is solved using an enforced regularization method. Theoretical verification is presented and actual experiment cases are tested, showing reliable accuracy and flexibility for large aviation structural parts. The underlying principle of the method provides an important reference for predicting and compensating workpiece deformation caused by residual stress using dynamic machining monitoring data in the context of digital and intelligent manufacturing.

库存材料内部的残余应力是与制造零件的几何/尺寸稳定性和疲劳寿命方面的质量相关的基本属性。对于必须满足高精度要求的大型零件，准确测量和预测残余应力场一直是一项重大挑战。现有的残余应力场测量技术要么是基于应变的测量方法，要么是效率和精度较低的非破坏性方法。本文报告了一种基于变形力推断残余应力场的新的非破坏性方法。在所提出的方法中，工件的残余应力场是根据变形力的特征来推断的，变形力反映了材料去除操作后不平衡残余应力场的整体影响。基于虚功原理对变形力与残余应力场之间的关系进行建模，并使用强制正则化方法解决残余应力场推理问题。进行了理论验证和实际实验案例测试，表明大型航空结构件具有可靠的精度和灵活性。该方法的基本原理为数字化和智能制造背景下利用动态加工监测数据预测和补偿残余应力引起的工件变形提供了重要参考。进行了理论验证和实际实验案例测试，表明大型航空结构件具有可靠的精度和灵活性。该方法的基本原理为数字化和智能制造背景下利用动态加工监测数据预测和补偿残余应力引起的工件变形提供了重要参考。进行了理论验证和实际实验案例测试，表明大型航空结构件具有可靠的精度和灵活性。该方法的基本原理为数字化和智能制造背景下利用动态加工监测数据预测和补偿残余应力引起的工件变形提供了重要参考。