Prediction of shape deviations in machining

During machining the workpiece surface layer is plastically deformed and acts as a source of residual stress for the entire cross section of the workpiece and as a consequence shape deviations occur. In this paper a new method to predict the shape deviation of machined workpieces with complex geometry is proposed. It combines experimental results of machining workpieces with simple geometries with finite element simulations. This is achieved by making use of the known source stresses in simple parts for which the approach is validated. Finally it is applied to predict the shape deviation of a ground linear rail guide.