Investigation of Residual Stress Distribution and Its Influence on Machining Deformation in 6061‑T651 Aluminum Alloy Plates Using Crack Compliance Method

To investigate the residual stress distribution and its influence on machining deformation in 6061‑T651 aluminum alloy plates， this paper uses the crack compliance method to study the residual stress characteristics of 6061-T651 aluminum alloy plates with a thickness of 75 mm produced by two domestic manufacturers in China. The results indicate that both types of plates exhibit highly consistent and symmetrical M‑shaped residual stress profile along the thickness direction， manifested as surface layer compression and core tension. The strain energy density across all specimens ranges from 1.27 kJ/m³ to 1.43 kJ/m³. Machining deformation simulations of an aerospace component incorporating these measured stresses showed minimal final deformation difference between the material sources， with a maximum deviation of only 0.009 mm across specimens. These findings provide critical data for material selection and deformation control in aerospace manufacturing.