In recent years, laser metal deposition (LMD) has attracted significant attention as a highly flexible metal 3D printing technology because of unrestricted component size and shape, unlike a typical powder bed process. However, the large temperature gradient experienced by the material, and the consequent thermal expansion and contraction during the local heating and rapid cooling by the interaction with the laser cause high residual stresses in deposited layer and substrate. This high residual stress can cause large deformation and microcracks which can have a negative impact on fatigue life. In this study, the residual stress of the repaired cylindrical rod by LMD was experimentally evaluated by Sachs method which calculates residual stress from strain release during hole drilling. Furthermore, the repair process of cylindrical rod was numerically simulated by using coupled transient thermal-structural analysis, which considered conductive, convective, and radiative heat transfer as well as phase transformations. The LMD process was modeled using an element birth-and-death algorithm [1], where each deposition layer is represented as a virtual element. Its stiffness and thermal properties are activated when the laser irradiation regions overlap. As a result, a trend of increasing residual stress values from the center of the cylinder toward the LMD surface was confirmed in both experiment and simulation results. Additionally, the effects of laser power and scanning speed on residual stress were investigated. It was found that the residual stress value showed little change with varying laser power, while it tended to decrease as the scanning speed increased.