I'm making a Decora-style wall outlet cover in 303 stainless.
The side "walls" are 2.4 mm wide, and the "wall height" is 4.4 mm, the face plate is 2.2 mm thick.
Here's a picture:
And a bit of the sketch of the Fusion 360 model:
I make this out of 3/8" flat bar 2.5" wide 303 stainless steel on a home CNC mill, using a vise as workholding, and flood coolant.
The face is machined with a facing operation with a 3/8" 4 flute end mill on the front side, and scooped out with the same mill and an adaptive operation on the back/inner side.
Once it comes off the vise, it's square. Right after, I use an orbital sander on the front to give it a more brushed look (WD40 and 120 grit sandpaper,) and after that, the plate is warped, as if the front face has expanded, or the side "walls" contract. There's about a 0.5-0.8 mm height difference between the edges and the center -- very pronounced!
The sanding is not particularly heavy, and the part isn't particularly warm after sanding.
What makes it warp like this, and what can I do in my design or machining to avoid this happening?