Xiaoliang Jin, University of British Columbia

Title: Residual Stress Development in Hybrid Additive-Subtractive Manufacturing

Abstract

Residual stress development is a central challenge in hybrid additive-subtractive manufacturing because it directly affects dimensional accuracy, surface integrity, mechanical reliability, and corrosion performance. This presentation provides an integrated view of residual stress evolution across additive deposition and subsequent machining, focusing on recent advances in modeling, experimentation, and microstructure-informed analysis. First, analytical and numerical frameworks for directed energy deposition are introduced to predict temperature history, stress distribution, and distortion in thin-wall structures under varying process parameters and deposition strategies. The discussion then extends to functionally graded materials, where material transition paths and gradient geometries strongly influence residual stress states. Attention is further given to post-machining of additively manufactured alloys, showing how initial stress fields and microstructural features govern the final surface residual stress after cutting. Finally, a constitutive modeling approach is presented to connect additive-manufacturing-induced microstructure with machining behavior. Together, these studies establish a foundation for designing hybrid manufacturing routes that achieve improved residual stress control and component performance.