The aim of this work is to develop a procedure for determining the three-dimensional residual stress fields in forged cylindrical pressure vessels. The procedure involves the destructive machining of the cylinder. Strain gauges record the strain variation on the outer surface of the cylinder as the inner surface is machined. A finite element model is then constructed, reversing the machining sequence, matching the increments in measured strain, and thus cumulatively arriving at the original distribution of residual stress. Examples include a numerical simulation for a thick disk and a practical application to thick-walled forged cylinders.
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