How engineers can measure and manage manufacturing stress levels

Stress is something we all must manage, particularly in the workplace. For engineers, however, stress extends beyond personal well-being to the physical stresses locked within materials in engineering components. These are known as residual stresses – a major challenge in manufacturing.

31/03/2025 12:30:03

Understanding residual stresses
Residual stresses (RS) have long been recognised in engineering design and manufacturing, but remain a relatively niche research area. In simple terms, residual stresses are the internal stresses present in a part or component when no external load is applied.

Thermo-mechanical manufacturing processes – such as forging, forming, heat treatment, and machining – induce these stresses, which must be controlled to prevent cracking and distortion, while enhancing performance.

Read the full article in DPA's April 2025 issue