The main problems in machining of thin-walled parts made of high-strength aluminum alloys are distortion and dimensional instability, which lead to an increase in distorted part scraps and production costs. This article attempts to investigate the correlation between machining-induced and quench-induced residual stresses and the distortion of thin-walled parts made of AL7075 alloy. The experiments are carried out in two steps. In the first step, the effects of polymer and uphill quenching methods in comparison with water quenching in the reduction of residual stresses are investigated on an experimental basis. By conducting the machining tests, the effect of residual stress on distortion is investigated. In the second step, several experiments are carried out under different machining conditions. To study the effect of mechanical and thermal loads on the residual stresses and distortion, the machining force and temperature of cutting area are measured. Finally, the correlation between the machining-induced residual stress and distortion is studied by measurement of stress on some parts. The results indicate that both machining and quench-induced residual stresses are effective in distortion of thin walled parts.