Inversion of speckle interferometer fringes for hole-drilling residual stress determinations

Speckle interferometric fringe patterns record stress-relief displacements induced by the drilling of blind-holes into prestressed objects. The quantitative determination of residual stress state from such stress patterns is difficult because of the ambiguity in the order of the observed fringes. The plane stress magnitudes are provided directly from selected fringe positions using a stochastic, iterative least squares minimization approach. The inversion requires prior knowledge of the experimental geometry and an appropriate uniaxial stress-relief displacement basis function derived from three-dimensional finite element calculations. Superpositioning of the rotated and scaled displacement basis functions allows the stress-relief relaxation for any biaxial state of stress to be determined. In this paper, fringe patterns were forward modeled from a large ensemble of calculated biaxial stress-relief displacement fields. Inversion of these noise-free fringe patterns reproduced the biaxial stresses with negligible error. Analysis of more realistic fringe patterns that include speckle noise gave stress magnitude errors that diminished rapidly with the number of selected points to better than 3 percent for 100 points. Sensitivity of the optical method is influenced by a number of factors, but the ensemble of model fringe patterns studied indicates that the stress magnitudes (nomalized with respect to the material's Young's modulus) from 3×10^–4 to 10^–2 can accurately be determined with visible laser radiation. The method is amenable to automation and can easily be extended to study near surface gradients in the residual stresses or applied to other optical recording techniques such as moiré and phase-shifting interferometry.     

Experimental Evaluation of Residual Stresses in Pipes Manufactured by UOE and ERW Processes

Pipes are basic elements used in the construction of pipelines for the long-distance transportation of oil and gas and their derivatives. They can be manufactured by cold forming processes such as UOE and ERW, both widely used in the oil and gas industry. These processes produce high levels of non-uniform plastic deformation, which introduce a new state of residual stress into the material. In some cases, these stresses combine with mechanical stresses generated by external loads leading to service failures, interrupting the transmission line and increasing the risk of accidents. Therefore, determining in advance the residual stress distribution in pipes is an important task which involves the evaluation of the structural integrity. Six pipe samples obtained by the UOE and ERW processes were measured and evaluated using a portable optical device that combines radial in-plane digital speckle pattern interferometer (DSPI) with the incremental hole-drilling technique to measure residual stresses. The experimental results indicate a distinct residual stress distribution for each manufacturing process, while the measured residual stress distributions in the longitudinal and circumferential directions were similar at all measurement locations along an individual pipe.     

饱和土地基在简谐荷载作用下的解析分析

基于多孔介质混合物理论,用解析的方法研究了不可压饱和土地基受到简谐荷载作用下的动力响应问题。利用Fourier积分变换求解耦合方程组,得到了二维饱和土介质在简谐荷载作用下的通解。针对表面透水的具有下卧基岩的饱和土层以及半无限饱和土地基的边界条件,获得了固体骨架位移、孔隙流体位移、固体骨架有效应力以及孔隙流体压力的积分形式解答,并通过数值算例分析了饱和土地基在简谐荷载作用下的响应。     

Mixed-mode stress intensity factors of 3D interface crack in fully coupled electromagnetothermoelastic multiphase composites

This contribution presents an extended hypersingular intergro-differential equation (E-HIDE) method for modeling the 3D interface crack problem in fully coupled electromagnetothermoelastic anisotropic multiphase composites under extended electro-magneto-thermo-elastic coupled loads through theoretical analysis and numerical simulations. First, based on the extended boundary element method, the 3D interface crack problem is reduced to solving a set of E-HIDEs coupled with extended boundary integral equations, in which the unknown functions are the extended displacement discontinuities. Then, the behavior of the extended singular stress indices around the interface crack front terminating at the interface is analyzed by the extended main-part analysis. The extended stress intensity factors near the crack front are defined. In addition, a numerical method for a 3D interface crack problem subjected to extended loads is proposed, in which the extended displacement discontinuities are approximated by the product of basic density functions and polynomials. Finally, the radiation distribution of extended stress intensity factors at the interface crack surface are calculated, and the results are presented toward demonstrating the applicability of the proposed method.     

A general framework for identification of hyper-elastic membranes with moiré techniques and multi-point simulated annealing

This paper presents a hybrid procedure for mechanical characterization of hyper-elastic materials based on moiré, finite element analysis and global optimization. The characterization process is absolutely general because does not require any assumption on specimen geometry, loading or/and boundary conditions.The novel experimental approach followed in this research relies on a proper combination of intrinsic moiré and projection moiré which allows 3D displacement components to be measured simultaneously and independently using always the same experimental setup and just one single camera. In order to properly compare experimental data and finite element predictions, 3D displacement information encoded in moiré patterns which are relative to the deformed configuration taken by the specimen are expressed in the reference system of the unloaded state.A global optimization algorithm based on multi-level and multi-point simulated annealing which keeps memory of all best records generated in the optimization is used in order to find the unknown material properties through the minimization of the Ω functional built by summing over the differences between displacements measured experimentally and those predicted numerically.Feasibility, efficiency and robustness of the proposed methodology are demonstrated for both isotropic and anisotropic specimens subject to increasing pressure loads: a natural rubber membrane and a glutaraldehyde treated bovine pericardium patch, respectively. Remarkably, the results of the characterization process are in very good agreement with target data independently determined. For the isotropic specimen, the maximum error on hyper-elastic constants is less than 1% and the residual error on displacements is less than 3.5%. For the anisotropic specimen, the maximum error on material properties is about 3.5% while the residual error on displacements is less than 3%. The identification process fails or becomes less reliable if “local” displacement values are considered.     

Surface Decoration for Improving the Accuracy of Displacement Measurements by Digital Image Correlation in SEM

In-situ straining experiments and residual stress evaluations by micromachining require accurate measurement of surface displacements. Such measurements can be conveniently done using Digital Image Correlation (DIC). Three surface decoration techniques are presented to enhance surface deformation and residual stress measurement capabilities on micron-scale samples within a Scanning Electron Microscope—Focused Ion Beam (SEM-FIB) instrument. They involve the use of Yttria-stabilized-zirconia nano particles applied chemically, nano platinum dots applied using FIB, and Focused Electron Beam (FEB) assisted deposition. The three decoration techniques create distinctive, random surface features that can be used with Digital Image Correlation to provide full field maps of surface displacements at high magnifications. A series of experiments using a FEGSEM-FIB demonstrated the effectiveness of the three surface decoration techniques for FEGSEM imaging at magnifications from 2,000× to 60,000×. The precision of the image correlation is substantially enhanced by the surface decoration, with displacement standard deviations reduced to the 0.005–0.03 pixel range, depending on the patch size used. By means of an example application, the use of surface decoration for microscopic hole-drilling residual stress measurements within a FIB-SEM is presented. The same trends in DIC uncertainty observed in the analysis of the surface decoration patterns carried through to the example application. Guidelines are given for appropriate choice of decoration method to suit various practical applications.     

MEASUREMENT OF NON-UNIFORM RESIDUAL STRESSES BY COMBINED MOIRE INTERFEROMETRY AND HOLE-DRILLING METHOD： THEORY, EXPERIMENTAL METHOD AND APPLICATIONS

Hole-drilling method is one of the most convenient methods for engineering residual stress measurement. Combined with moiré interferometry to obtain the relaxed whole-field displacement data, hole-drilling technique can be used to solve non-uniform residual stress problems, both in-depth and in-plane. In this paper, the theory of moiré interferometry and incremental hole-drilling (MIIHD) for non-uniform residual stress measurement is introduced. Three dimensional finite element model is constructed by ABAQUS to obtain the coefficients for the residual stress calculation. An experimental system including real-time measurement, automatic data processing and residual stresses calculation is established. Two applications for non-uniform in-depth residual stress of surface nanocrystalline material and non-uniform in-plane residual stress of friction stir welding are presented. Experimental results show that MIIHD is effective for both non-uniform in-depth and in-plane residual stress measurements. The project supported by the FRAMATOME ANP     

Experimental determination of stress intensity factors due to residual stresses

An experimental method is presented that enables stress intensity factors due to residual stress to be determined directly, without prior determination of the residual stress. The method is based on the crack compliance method, where a narrow cut is introduced progressively into the considered component, and the resulting strain change is measured by a strain gage. The required mathematical relations to determine stress intensity factors from strain measurements are established by means of some basic relations of linear elastic fracture mechanics. They are derived explicitly for two exemplary geometrical systems, which allowed for analytical treatment. Experimental data obtained in the case of a steel roller are presented and discussed.     

A finite-element technique to analyze the data measured by the hole-drilling method

A finite-element technique to analyze the data obtained by the hole-drilling strain-gage method is presented. In this study, residual stresses are assumed as initial stresses existing in the structural material or component. It is also assumed that the elimination of the initial stresses in the region of the drilled hole changes the measured strains. After putting initial stresses into displacement finite-element equations and comparing the stiffness matrix and the initial stresses matrix with those of the previous increment, equations relating unknown initial stresses and measured strains were obtained. By solving these equations, residual stresses were obtained. In this paper three examples are studied. In the first two examples, calibration constants C1 to be used in determining residual stress were calculated which varied with depth. In the third example, the data obtained by using the hole-drilling method are analyzed. All examples show good agreement with previous studies. Using the present method allows greater flexibility of choice of specimen shape, materials, and experimental procedure than would be possible if only analytic solutions were used.     

模糊桁架结构有限元分析的随机因子法

研究模糊桁架结构在模糊力作用下的有限元分析方法。考虑桁架结构材料物理参数、几何尺寸和外荷载同时为模糊变量，利用信息熵将模糊变量转变为随机变量。基于随机因子法，利用代数综合法推导出结构位移和应力响应的均值、方差的计算表达式。通过算例，分析了结构物理参数、几何尺寸和外荷载的模糊性对结构位移和应力响应的影响，并验证了本文模型和方法的合理性与可行性。本方法的优点是能够反映结构某一参数的模糊型对结构响应的影响。     

A New Procedure to Measure Near Yield Residual Stresses Using the Deep Hole Drilling Technique

Mechanical strain relief techniques for estimating the magnitude of residual stress work by measuring strains or displacements when part of the component is machined away. The underlying assumption is that such strain or displacement changes result from elastic unloading. Unfortunately, in components containing high levels of residual stress, elastic-plastic unloading may well occur, particularly when the residual stresses are highly triaxial. This paper examines the performance of one mechanical strain relief technique particularly suitable for large section components, the deep hole drilling (DHD) technique. The magnitude of error is calculated for different magnitudes of residual stress and can be substantial for residual stress states close to yield. A modification to the technique is described to allow large magnitudes of residual stress to be measured correctly. The new technique is validated using the case of a quenched cylinder where use of the standard DHD technique leads to unacceptable error. The measured residual stresses using the new technique are compared with the results obtained using the neutron diffraction technique and are shown to be in excellent agreement.     

简支及悬臂箱梁在角隅轴向荷载作用下的翼板纵向应力

基于能量变分原理，拟定轴向荷载作用下箱梁的纵向位移函数，得到关于翼板剪切变形引起的位移差函数的基本微分方程，继而推导出箱梁翼板纵向应力表达式，并首次得出角隅轴向荷载作用下翼板出现应力不均匀分布的荷载及边界条件。通过对一模型箱梁进行计算，并与通用有限元软件ANSYS壳单元计算结果进行比较，验证了该方法和所推导公式的正确性。研究结果表明，当作用于简支箱梁截面角隅处的轴向荷载（合力无偏心）为集中或分布荷载时，翼板不产生纵向应力不均匀现象；当作用于悬臂箱梁截面角隅处的轴向荷载（合力无偏心）为集中荷载时，翼板不产生纵向应力不均匀现象，而当荷载轴向分布时，翼板将产生纵向应力不均匀现象。实际工程中，横力弯曲使悬臂箱梁产生剪力滞效应，这种效应会与轴向分布荷载产生的效应叠加，设计时对此应予以充分考虑。     

Application of hypersingular integral equation method to three-dimensional crack in electromagnetothermoelastic multiphase composites

A three-dimensional crack problem in electromagnetothermoelastic multiphase composites (EMTE-MCs) under extended loads is investigated in this paper. Using Green’s functions, the extended general displacement solutions are obtained by the boundary element method. This crack problem is reduced to solving a set of hypersingular integral equations coupled with boundary integral equations, in which the unknown functions are the extended displacement discontinuities. Then, the behavior of the extended displacement discontinuities around the crack front terminating at the interface is analyzed by the main-part analysis method of hypersingular integral equations. Analytical solutions for the extended singular stresses, the extended stress intensity factors (SIFs) and the extended energy release rate near the crack front in EMTE-MCs are provided. Also, a numerical method of the hypersingular integral equations for a rectangular crack subjected to extended loads is put forward with the extended displacement discontinuities approximated by the product of basic density functions and polynomials. In addition, distributions of extended SIFs varying with the shape of the crack are presented. The results show that the present method accurately yields smooth variations of extended SIFs along the crack front.     

Measurement of Applied Stresses and Residual Stresses on a Residual Stress Model by Applying Two Different Loads

Applied stresses on a residual stress model have previously been obtained by measuring the residual stresses and the resultant stresses generated by applying a load. The present paper reports that the applied stresses and the residual stresses on the residual stress model can be obtained by measuring two resultant stresses generated by applying loads of two different magnitudes. In the proposed method, the residual stresses need not be obtained from the residual stress model before applying a load. The residual stress model used to test the proposed method is a circular disk with frozen stresses that is subjected to a diametral compressive load at a certain angle. The applied stresses and the residual stresses on a residual stress model were experimentally and precisely obtained by digital photoelasticity using linearly polarized light.     

A numerical analysis of cracks emanating from an elliptical hole in a 2-D elasticity plate

This paper is concerned with the stress intensity factors (SIFs) of cracks emanating from an elliptical hole in an infinite or a finite plate under biaxial loads by using a boundary element method, which consists of the non-singular displacement discontinuity element presented by Crouch and Starfield and the crack-tip displacement discontinuity elements due to the author. In the boundary element implementation the left or the right crack-tip element is placed locally at the corresponding left or right crack tip on top of the constant displacement discontinuity elements that cover the entire crack surface and the other boundaries. A few numerical examples are included to show that the present approach is very efficient and accurate for the calculating the SIFs of crack problems in an infinite or a finite plate. The present numerical results of cracks emanating from an elliptical hole under biaxial loads can reveal the effect of the elliptical aspect ratio and the transverse load on the SIFs.     

Blind-hole residual stress determination using optical interferometry

The in-plane method and the out-of-plane method are used to analyze blind-hole residual stress as measured by optical interferometry. The in-plane method, which constructs a relation between the in-plane displacement field and the residual stress released from blind-hole drilling, is applicable when the sensitivity vector of the interferometer used in the measuring system is parallel to the object surface. Three in-plane displacements obtained from one interference pattern are sufficient to determine the residual stress. The out-of-plane method, which establishes a new relation between the out-of-plane displacement field and the released residual stress, is suggested when the sensitivity vector is perpendicular to the object surface. Two relative out-of-plane displacements extracted from one interference pattern are sufficient to determine the residual stress. With the adoption of these two methods, interpolating calculation is not needed to determine the fringe order of each data point, since the selections of the required data points are flexible using these two methods. Two experiments, one for the in-plane method and the other for the out-of-plane method, were carried out to illustrate the applicability and usefulness of these two methods.     

喷丸镍基合金材料微区残余应力的切槽法测量研究

本文结合聚焦离子束-电子束(Focused ion beam-electron beam,简称FIB-EB)双束系统和真空镀膜工艺,进行微区散斑的制备工艺研究,并将所发展的微散斑制备工艺应用于喷丸镍基合金材料表面制斑,进而结合切槽法进行残余应力高温释放规律的测量研究。在FIB-EB双束系统下记录切槽前后制斑微区的图像,利用数字图像相关法计算切槽后的位移,结合InglisMuskhelishvili理论公式可计算得到残余应力。文中研究了不同温度及保温时间对残余应力释放的影响规律。结果表明,残余应力随保温时间的增长释放速度逐渐减小,最后残余应力趋于稳定值。同时,温度越高,残余应力释放越彻底,800℃下近乎完全释放。该工艺具有适用性好,效率高等优点,可望在材料微区变形测量中得到进一步应用。     

An effective boundary element method for analysis of crack problems in a plane elastic plate

A simple and effective boundary element method for stress intensity factor calculation for crack problems in a plane elastic plate is presented. The boundary element method consists of the constant displacement discontinuity element presented by Crouch and Starfield and the crack-tip displacement discontinuity elements proposed by YAN Xiangqiao. In the boundary element implementation the left or the right crack-tip displacement discontinuity element was placed locally at the corresponding left or right each crack tip on top of the constant displacement discontinuity elements that cover the entire crack surface and the other boundaries. Test examples (i. e. , a center crack in an infinite plate under tension, a circular hole and a crack in an infinite plate under tension) are included to illustrate that the numerical approach is very simple and accurate for stress intensity factor calculation of plane elasticity crack problems. In addition, specifically, the stress intensity factors of branching cracks emanating from a square hole in a rectangular plate under biaxial loads were analysed. These numerical results indicate the present numerical approach is very effective for calculating stress intensity factors of complex cracks in a 2-D finite body, and are used to reveal the effect of the biaxial loads and the cracked body geometry on stress intensity factors.     

双轴载荷作用下源于椭圆孔的分支裂纹的一种边界元分析

利用一种边界元方法来研究双轴载荷作用下无限大板中源于椭圆孔的分支裂纹．该边界元方法由Crouch与Starfied建立的常位移不连续单元和笔者提出的裂尖位移不连续单元构成．在该边界元方法的实施过程中,左、右裂尖位移不连续单元分别置于裂纹的左、右裂尖处,而常位移不连续单元则分布于除了裂尖位移不连续单元占据的位置之外的整个裂纹面及其它边界,文中算例说明本数值方法对计算平面弹性裂纹的应力强度因子是非常有效的。该文对双轴载荷作用下无限大板中源于椭圆孔的分支裂纹的数值结果进一步证实本数值方法对计算复杂裂纹的应力强度因子的有效性,同时该数值结果可以揭示双轴载荷及裂纹体几何对应力强度因子的影响。     

Investigation of displacement fields in an abrasive waterjet drilling process: Part 2. Numerical analysis

In this paper, the displacement fields associated with the abrasive waterjet (AWJ) drilling process were simulated using the finite element method. A threedimensional finite element model was established, and justifiable pressure loads were used in the numerical model to simulate the AWJ drilling process. It was assumed that the pressure load in the AWJ could be resolved into three components, such as impact jet pressure, shear and normal pressure. The effect of these three pressure loads and their magnitudes on the surface displacement were investigated as a function of the jet penetration depth through numerical modeling. Using the hybrid experimental-numerical stress analysis approach, the transient state of stress and strain associated with the notch crest of the jet-induced hole at the impingement zone of the target material during AWJ piercing can be modeled numerically. It was found that the shear contributed the most in shaping the displacement contour patterns and that the jet pressure did not play a dominant role in determining theu field displacement. The jet pressure and shear had the most effect on thev field displacement contour pattern. It was demonstrated that the principal stresses at the bottom of the cavity increase as the depth of the hole increases.