Although it is generally understood that there are different Levels of residual stresses RS in a material (from 1.order to 3.order, between grains to internal ones) there has been no relation to complex geometry been reported as far as I know. However RS leads to distortion and part distortion is related to geometry and size (symmetry vs. asymmetry) meaning RS Distribution over the shape and  cross section of the part.   

Zoch, H.-W.: From Single Production Step to Entire Process Chain – the Global Approach of Distortion Engineering, presented at the 1st Int. Conf. on Distortion Engineering IDE 2005, Bremen, Germany, Sept. 14–16, 2005, P. 3–10.

Zoch, H.-W.: Distortion engineering: vision or ready to application? Mat.-wiss. u. Werkstofftech. (2009) 40, No.5-6, p. 342-348.

Residual stress is a lock in stress. In this case I feel the residual stresses generated due to the following reasons:

1. Temperature generated due to grinding which generate a temperature gradient through the thickness which results in uneven expansions and contractions of the material due to which the residual stresses are generated in the object.

2. If the temperature gradient will be high then the residual stress will be high.

I feel that is the main reason for this.

The residual strains may have two origins; 1) , the elastic strains, which can be partially  recovered by the spontaneous formation surface undulations and ripples if the specimen enclosed by the free surfaces and boundaries. The phenomena is called strained releave, which can be enhanced drastically at high temperatures by surface diffusion driven by the residual surface stresses. 2) The plastic strains generated by the formation of dislocations and point defects even stacking fold during the heavy cold work or grinding. That is the main source of the  residual stresses present in the body generated during severe plastic deformation caused by the grinding operation. For this case, The strain relief can be possible only by the recovery and recrystallization, which are strongly temperature dependent. 

 Geometry becomes important ; Where the sharp corners and edges produced during the grinding become later main stress risers, which can initiate the crack formation or flaws that ends up with the premature failure of the body.  

There are several accepted methods to measure the residual stress of an object, from Neutron scattering measurements and X-ray diffraction measurements to contour measurements (measurement of distortion after processing/relaxation) and hole drilling methods etc.

There are a lot of publications out there regarding the measurement of Residual Stress.

good luck!

If you have a brittle ceramic it also means that the implementation of dislocations is unlikely since the material is rather cleaving than plastically deforming (formation of dislocations). The more complicated a crystal structure becomes the less probable is a dislocation formation (in a classicle meaning) since the Burgers vectors are too big. And temperature formed during grinding is from my point of view also related to "inner friction". From my point of view this problem is much more complex that described by a very straight correlation. Already the definition of stress (as explained above) and the misuse of terms like strain and stress already shows that it is necessary to understand what these terms atually mean and what we measure and conclude from this. Any deviation from these assumptions like strong gradiants along edges or corners where the deformation conditions are totally different than on a flat surface will of course affect the used model and ...fail. We are still only able to develop models as copy of observed phenomena. It does not mean if a model is good it describes nature correctly. It only tells us that fullfilling the conditions of this model the simulated result (hopefully) describes the observed phenomenon correctly. Finally everything (my personal view) happens ono atomic scale. We can apply FE simulations with an acceptable correlation. But they don't describe what really happens. They are only our presently available tools to simulate this since everything else is too time consuming or still too complicated. If you draw a crystal structure you also use spheres...and you certainly don't believe that an atom looks like a sphere, do you?

residual stresses are developed due to rise in temperature generated during grinding, very complex stress conditions during developed during grinding like mechanical compression, shear, tensile etc. uneven heat distribution due to ceramic material etc.

yes, becoz, residual stresses are functions of changes in lattice parameters.

(Macro) residual stress state on the component depends on a series of complicated interactions between geometry, material properties and processing conditions. There is no universal solution for this problem and each problem has to be treated independently. Fortunately, if the suggested process has only a local effect, the problem might be treated as geometry independent problem. For example, cylindrical grinding of a medium sized shaft may induced surface stresses which are practically only dependent on the material and the process parameters. However, if the diameter is varied significantly, you can get significant changes. In that case, I would suggest to investigate the underlying physics in generation of residual stress to estimate the possible impact. If the process is relatively easy to simulate, the simulation will also provide some insight. Unfortunately, you can only be sure by varying processing parameters and measuring the residual stress. In fact, if you have adequate equipment and knowledge, performing experiments and measurements is faster than going through simulations. 

Hi, 

Intricate shapes/ sharp dimensional changes are one of the key parameters directly influencing the level of residual stresses. Apart from that, the microstructure/phases can have impact on residual stresses. For example quenching increases residual stresses therefore annealing can relieve them.

There are number of parameters to be considered not only geometry!

Abdul 

I my opinion you are more likely to relieve residual stress, and therefore see some deformation after the grind process. 

If you  are using very small abrasives (example,