Aircraft engine components that are machined from cast and wrought or powder material forgings represent a significant weight and cost of both military and commercial engines. The forged material weight is typically 4 – 10 times the finished part weight. The excess material is removed by various machining operations, which are a major contributor to the cost of forged components. Heat treatment and machining are two critical manufacturing operations. Nickel base super-alloys are heat treated following forging, a process that involves quenching from near the solvus temperature. Thermal gradients during quenching cause plastic deformation and residual stress build-up, which lead to distortion following quench and later during machining. The objective of the present work is to develop a modeling method that predicts machining distortions of 2-D axisymmetric parts. The procedure has been implemented on industrial strength software (DEFORM-HT) so that it is readily available to the aerospace industry and their suppliers. The method realistically captures the process boundary conditions (tooling constraints) for any user-specified sequence of machining operations. The method has been rigorously validated first on simple shapes in a well-controlled situation and then extended to complex shapes in a production environment. This work will advance the state-of-the-art in going from the present state of a time-consuming, manual, partially validated procedure to an automated, high productivity, user-friendly, fast-acting, validated, commercially supported, and production ready analysis tool which can be used to achieve significant cost savings. This program is funded by the USAF Metals Affordability Initiative (MAI).