The paper reviews a development of mathematical algorithms and implementation of mapping residual stress profiles from microscale to macroscale finite element (FE) models. A shot-peening simulation of Inconel 718 is conducted using the finite element method (FEM) to obtain the residual stress profiles which are used as an input in the developed mapping algorithms. Residual stress profiles induced by the shot-peening processes are mapped into different FE models including a perforated plate, a model with a complex surface, and an aero-engine vane component. The mathematical mapping algorithms and formulations are developed for 2D and 3D FE models where residual stress profiles obtained experimentally, numerically, or analytically for different manufacturing processes including shot-peening, water jet machining, milling, turning, roller burnishing, laser machining and peening, electro discharge machining, etc., can be mapped on FE models with complex geometries. The implementation and the results for the mapping techniques are presented and discussed in detail.

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