Abstract: The classification of residual stress (RS) and the corresponding method for simulation in each scale are summarized. The studies focusing on the evolution and regulation of RS are summarized to demonstrate the development in the field. The fruits from simulating the evolution of RS in large and complex components are demonstrated, taking the quenching process of a manipulator base as an example. The effect of reducing RS via compression in components with varying section is discussed, taking the die forging on an I-section bar as an example. The development of simulating & control technology of RS toward the applications along the whole life cycle, or in the assembled components, together with its potential to be integrated into the intelligent manufacturing, is predicted.

Key words: Large and complex components, Residual stress, Manufacturing distortion, Evolution and regulation