应用云纹干涉法测量冷挤压孔周残余应力分布

本文就冷挤压加工后紧固孔周的残余应力测量问题进行了研究。文中提出了径向切割法以释放欲求剖面的周向残余应力;采用高灵敏度的云纹干涉法测量残余应力释放后引起的附加变形;用载波错位法获得高反差的应变条纹图。     

A new rosette design for more reliable hole-drilling residual stress measurements

A new six-element strain gage rosette is presented that can greatly improve residual stress measurement accuracy when using the hole-drilling method. The proposed rosette consists of three pairs of sector-shaped radial and circumferential gages connected as half-bridges. This rosette design increases effective strain sensitivity by a factor of 2.3 compared with a standard ASTM rectangular rosette, and can identify stresses at one-third greater depths from the measurement surface. Experimental measurements confirm theoretical strain response calculations within 3–4 percent. Apart from a small increase in time to complete the electrical connections, the practical use of the proposed rosette is identical to that of a conventional three-element rosette.     

Residual-stress determination by single-axis holographic interferometry and hole drilling—Part I: Theory

A method is described for the rapid, accurate determination of residual stresses from a holographic interference fringe pattern. The pattern is generated by the displacement field caused by localized relief of residual stresses via the introduction of a small, shallow hole into the surface of a component or test specimen. The theoretical development of the holographic method is summarized. An example is given showing how the method can be applied to a typical experimentally observed fringe pattern to determine principal residual stresses and directions.     

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.     

Two Dimensions Residual Stresses Analysis Through Incremental Groove Machining Combined with Electronic Speckle Pattern Interferometry

In this study a new residual stress determination method in two directions simultaneously is presented. This method is based on stresses relaxation in a groove that is machined incrementally. The residual stresses relaxation occurs simultaneously from both the depth and the length of the groove. Thus, measuring the surface strain field generated by the relaxation enables to determine the stress gradient both along the depth and the length of the groove. To measure the surface strain in a direction perpendicular to the groove, a digital speckle pattern interferometer is used. This method is suitable when the residual stress field in the structure varies in the depth as well as along the surface of the part, like for example in a welded structure. The method is tested here on an aluminium plate in which a central band has been shot peened.     

Thermoelastic analysis of functionally graded annulus with arbitrary gradient

A thermoelastic problem of a circular annulus made of functionally graded materials with an arbitrary gradient is investigated. Different from previous works, our analysis neither requires a special form of the gradient of material properties nor demands partitioning the entire structure into a multilayered homogeneous structure. Instead, we propose a new method for solving the thermoelastic problem of a functionally graded circular annulus by transforming it to a Fredholm integral equation. The distribution of thermal stresses and radial displacement can be obtained by solving the resulting equation. Illustrative examples are given to show the effects of varying gradients on the thermal stresses and radial displacement for given temperature changes at the inner and outer surfaces. The results indicate that the thermal stresses can be relaxed for specified gradients, which is beneficial to design an inhomogeneous annulus to maintain structural integrity.     

Stresses in rotating heterogeneous viscoelastic composite cylinders with variable thickness

An analytical solution is presented for the rotation problem of a two-layer composite elastic cylinder under a plane strain assumption. The external cylinder has variable-thickness formulation, and is made of a heterogeneous orthotropic material. It contains a fiber-reinforced viscoelastic homogeneous isotropic solid core of uniform thickness. The thickness and elastic properties of the external cylinder are taken as power functions of the radial direction. By the boundary and continuity conditions, the radial displacement and stresses for the rotating composite cylinder are determined. The effective moduli and Illyushin’s approximation methods are used to obtain the viscoelastic solution to the problem. The effects of heterogeneity, thickness variation, constitutive, time parameters on the radial displacement, and stresses are investigated.     

Residual-stress determination through combined use of holographic interferometry and blind-hole drilling

Holographic interferometry is used to determine in-plane radial displacements due to release of residual stresses by hole drilling. A method is derived for relating radial displacements measured in three directions of illumination to the state of residual stress, analogous to relations used in the conventional strain-rosette technique. Residual stress is produced by an interference fit of two circular tubes. Agreement between stress determined holographically with a computed value and with that determined by the conventional technique is good. Advantages of the holographic technique in overcoming various shortcomings of the conventional technique are discussed. A modification of the holographic technique involving data collection in only two directions of illumination is described.     

Determination of residual stresses by an optical correlative hole-drilling method

In conjunction with the incremental hole-drilling method, a new evaluation procedure is presented for determining the residual stress state in components. In contrast to the classical method, the whole displacement field around the drilled hole is measured using the electronic speckle pattern interferometry technique. The displacement patterns, measured without contact to the surface, are then correlated with those obtained by finite-element simulations using statistical methods. The simulated displacement patterns, used for calibration purposes, result from the application of properly defined basic loads. In this way, the values and the orientation of the residual stresses can be determined by superposition of these properly scaled and shifted basic loads. Even complex states of stress can be evaluated. The theoretical background and experimental results are presented.     

Analysis of residual stresses in cylindrically anisotropic materials

Metal-forming operations leave residual stresses in formed parts due to nonuniform deformation occurring during the process. An exact method of determining the longitudinal, radial and circumferential (tangential) residual stresses in axisymmetric specimens was proposed by Mesnager¹ and further developed by Sachs². The boring-out technique can be complemented by a similar procedure in which strains are measured on the inner surface of the tube when material is removed from the outer surface.The work proposed in this paper extends previous analyses of residual stresses to the case where the material exhibits cylindrical elastic anisotropy, i.e., the principal axes of anisotropy correspond to the longitudinal, radial and circum-ferential directions of the tube. In addition, the present analysis considers the case in which a residual-shear stress, developed by twisting the tube about its axis, exists in the tube. When such shearing stresses are present, the principal axes of the residual-stress distribution are not parallel to the principal axes of the tube.     

非稳态纯滚动接触弹塑性分析

建立了二维弹塑性非稳态循环纯滚动接触有限元模型.材料本构采用一种较好的循环塑性模型,并通过材料用户子程序在通用有限元软件ABAQUS中自定义该本构模型.通过在弹塑性无限半空间表面上重复移动随时间按简谐规律变化的赫兹法向载荷来模拟非稳态循环纯滚动接触过程.通过数值模拟,得到接触表面附近的残余累积变形、应变和残余应力.不同的最大赫兹接触压力对残余应力和残余应变影响较大.在简谐变化的法向接触载荷作用下接触表面的变形呈波浪形,随着滚动次数的增加,该波状表面沿载荷移动相反方向逐渐移动,但移动速率要衰减.波状表面波谷处的残余应力、应变和变形大于波峰处.随滚动次数的增加,残余应力增大但很快趋于稳定,残余应变也增大但增大速率衰减.     

Improvement of the Contour Method for Measurement of Near-Surface Residual Stresses from Laser Peening

A study was conducted to develop a methodology to obtain near-surface residual stresses for laser-peened aluminium alloy samples using the contour method. After cutting trials to determine the optimal cut parameters, surface contours were obtained and a new data analysis method based on spline smoothing was applied. A new criterion for determining the optimal smoothing parameters is introduced. Near-surface residual stresses obtained from the contour method were compared with X-ray diffraction and incremental hole drilling results. It is concluded that with optimal cutting parameters and data analysis, reliable near-surface residual stresses can be obtained by the contour method.     

Residual-stress measurement in orthotropic materials using the hole-drilling method

The hole-drilling method is used here to measure residual stresses in an orthotropic material. An existing stress-calculation method adapted from the isotropic case is shown not to be valid for orthotropic materials. A new stress-calculation method is described, based on the analytical solution for the displacement field around a hole in a stressed orthotropic plate. The validity of this method is assessed through a series of experimental measurements. A table of elastic compliances is provided for practical residual-stress measurements in a wide range of orthotropic materials.     

Measurement of the Distribution of Residual Stresses in Layered Thick-Walled GFRP Pipes

The objective of this study is to measure the axial, circumferential, shear and radial residual stress distributions in three thick-walled glass fibre reinforced plastic (GFRP) filament-wound pipes, two of which are layered. The measurement of residual stresses was carried out using a recently published layer removal method which overcomes the limitations of previous techniques and can be applied to layered anisotropic pipes of any wall thickness. Layers of approximately 0.3 mm thickness were incrementally ground from the outer surface of the pipes. The resulting strains were measured on the inner surfaces. A least-squares polynomial was fitted to each measured data set, and used to calculate the corresponding stress distributions. All of the resulting axial, hoop and shear stress distributions adhere to the requirement of self-equilibrium and the radial stress distributions all vanish to zero at the inner and outer surfaces. The radial stresses of the layered pipes showed a tendency to have two peaks, one for each layer, a consequence of the two-stage manufacturing process of these pipes. The measured axial and hoop stresses of all three pipes were similar at the inner surfaces despite significant differences in the stiffnesses in the principal directions arising from different wind angles.     

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.     

Calculation of an ejection explosion in a radial approximation

Equations are derived describing the motion of a medium with an ejection explosion, under the assumption that the medium is incompressible and moves in a radial direction away from the center of the explosion. Here account is taken of the tangential stresses between the moving layers of the medium. A comparison of the calculations of the velocities of the motion of the dome and the dimensions of the craters formed showed good agreement, both with model experiments on the ejection of sand, and with large-scale ejection explosions.     

Elastic stress analysis of rotating converging conical disks subjected to thermal load and having variable density along the radius

An analytical procedure for evaluation of elastic stresses and strains in rotating conical disks, either solid or annular, subjected to thermal load, and having a fictitious density variation along the radius is presented. The procedure is based on two independent integrals of the hypergeometric differential equation describing the displacement field; this procedure is just as general as the one found in technical literature, but less intricate and more reliable. General unpublished relations of stress state and displacement field in conical disk subjected, under elastic conditions, to thermal gradient, and featuring a density variation along the radius are defined. Particular consideration is given to some industrial example of turbine rotors carrying hub and rim with buckets on periphery or radial blades on lateral surfaces. The analytical results obtained by using the new general relations perfectly match those obtained by FEA.     

Time-dependent thermoelastic creep analysis of rotating disk made of Al–SiC composite

Time-dependent creep stress redistribution analysis of rotating disk made of Al–SiC composite is investigated using Mendelson’s method of successive elastic solution. All mechanical and thermal properties except Poisson’s ratio are radial dependent based on volume fraction percent of SiC reinforcement. The material creep behavior is described by Sherby’s constitutive model using Pandey’s experimental results on Al–SiC composite. Loading is an inertia body force due to rotation and a distributed temperature field due to steady-state heat conduction from inner to outer surface of the disk. Using equations of equilibrium, stress strain, and strain displacement, a differential equation, containing creep strains, for displacement is obtained. History of stresses and deformations are calculated using method of successive elastic solution. It is concluded that the uniform distribution of SiC reinforcement does not considerably influence on stresses. However, the minimum and most uniform distribution of circumferential and effective thermoelastic stresses belongs to composite disk of aluminum with 0% SiC at inner surface and 40% SiC at outer surface. It has also been found that the stresses, displacement, and creep strains are changing with time at a decreasing rate so that after almost 50 years the solution approaches the steady-state condition.     

Residual-stress determination of concentric layers of cylindrically orthotropic materials

Equations have been obtained for determining residual stresses in the wall of a hollow, axially symmetric body consisting of concentric layers of elastically dissimilar materials, all having cylindrical elastic orthotropy. These equations permit residual normal stresses in the radial, circumferential, and axial directions and residual shear stresses on planes normal to the axis of the body to be calculated from measurements of the strains developed on the inner or outer cylindrical surface of the body as thin layers of stressed material are serially removed from the outer or inner surfaces, respectively. The equations are applied to a parametric study of stresses in an elastically isotropic, two-component body to determine the nature of the differences in stresses between the composite body and a homogeneous body as a function of the difference in elastic constants.     

Application of a kinematic hardening viscoplasticity model with thresholds to the residual stress relaxation

The life analysis of engine components needs to take into account the residual stress relaxation induced by cyclic service loads. The paper recalls a new class of constitutive equations for cyclic viscoplasticity, using a series of kinematic hardening models with thresholds. The equations are introduced within a recently enlarged thermodynamic framework. Some attention is focused to the relations with multisurface approaches and to a specific determination procedure of the model parameters. The new model is applied to the calculation of the near surface residual stress relaxation after shot peening, when the structure is submitted to cyclic service loads. The simulated stabilized residual stresses are in good accordance with experimental results obtained on an N18 disk alloy at 650°C. In comparison, the classical model without threshold predicts the complete vanishing of the residual stresses, which is not satisfactory.