Residual stresses have been considered to be an important parameter when friction stir processing (FSP) tool is to be manufactured. FSP has often been used for surface modification and fabrication of surface composites. Involuntary residual stress in a designed tool may cause it to fail before due time. Because of this, the knowledge about the stresses on the tool probe after its machining has been considered to be desirable. The present research has focused on the analysis of the residual stresses on the tip and periphery of the FSP tool probe which has been manufactured using H13 tool steel material during the turning processes on a CNC lathe machine. The experiments have been performed on two different types of tool probes, namely circular, tapered circular probes. ABAQUS/CAE simulation has been performed for circular and tapered circular probe, as the provision of a sustainable, simple and reasonable model to analyze the machining processes (using ABAQUS/CAE software) has been the primary objective of this research. The results have been found to be within a close range of the experimental observations. The same model can thus be applied to other geometries.
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