An improved method of indent pairs is utilised to determine residual stresses in high speed milling specimens of AA 6082-T6 and AA 7075-T6 aluminium alloys. To carry out the measurement procedure, this approach does not need specific equipment but only requires a universal measuring machine and an oven. An indentation device is incorporated to the measuring machine, which allows reducing the absolute error of measurement to just ±0.9 MPa. The geometry of the tool and cutting parameters are selected to evaluate the sensitivity of the method. The residual stress distributions generated by high speed milling are exhaustively evaluated taking into account orthogonal components of cutting speed and tangential force, which are parallel and perpendicular to feed direction.

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