Residual Stress Measurement in Composite Laminates Using Incremental Hole-Drilling with Power Series

Current methods for incremental hole-drilling in composite laminates have not been successfully applied in laminates of arbitrary construction or where significant variation of residual stress exists within a single ply. This work presents a method to overcome these limitations. Series expansion is applied to each ply orientation separately so that the discontinuities in the residual stresses at ply interfaces can be correctly captured. Temperature variations described by power series are used to set up eigenstrains and consequent stresses which vary in the through-thickness direction. The calibration coefficients at each incremental hole depth are calculated through the use of finite element modelling. The inverse solution employs a least-squares approach which makes the resulting solution insensitive to measurement uncertainty. Robust uncertainties in the residual stress distributions are determined using Monte Carlo simulation. The residual stress distribution is found from that combination of series orders in the different ply orientations that has the lowest RMS uncertainty, selected only from those combinations that have converged. The method is demonstrated on a GFRP laminate of [0₂/+45/?45]_s construction where it is found that transverse cracking of the plies at the inner surface of the hole may have impacted on the accuracy of the results.     

Comparison Between Surface and Near-Surface Residual Stress Measurement Techniques Using a Standard Four-Point-Bend Specimen

Background

Determination of near-surface residual stresses is challenging for the available measurement techniques due to their limitations. These are often either beyond reach or associated with significant uncertainties.

Objective

This study describes a critical comparison between three methods of surface and near-surface residual stress measurements, including x-ray diffraction (XRD) and two incremental central hole-drilling techniques one based on strain-gauge rosette and the other based on electronic speckle pattern interferometry (ESPI).

Methods

These measurements were performed on standard four-point-bend beams of steel loaded to known nominal stresses, according to the ASTM standard. These were to evaluate the sensitivity of different techniques to the variation in the nominal stress, and their associated uncertainties.

Results

The XRD data showed very good correlations with the surface nominal stress, and with superb repeatability and small uncertainties. The results of the ESPI based hole-drilling technique were also in a good agreement with the XRD data and the expected nominal stress. However, those obtained by the strain gauge rosette based hole-drilling technique were not matching well with the data obtained by the other techniques nor with the nominal stress. This was found to be due to the generation of extensive compressive residual stress during surface preparation for strain gauge installation.

Conclusion

The ESPI method is proven to be the most suitable hole-drilling technique for measuring near-surface residual stresses within distances close to the surface that are beyond the penetration depth of x-ray and below the resolution of the strain gauge rosette based hole-drilling method.

     

Residual Stress Analysis on Thick Film Systems by the Incremental Hole-Drilling Method – Simulation and Experimental Results

The residual stress state in thick film systems, as for example thermal spray coatings, is crucial for many of the component’s properties and for the evaluation of the integrity of the coating under thermal and/or mechanical loading. Therefore it is necessary to be able to determine the local residual stress distribution in the coating, at the interface and in the substrate. The incremental hole-drilling method is a widely used method for measuring residual stress depth profiles, which was already applied for thermally sprayed coatings. But so far no reliable hole-drilling evaluation method exists for layered materials having a stress gradient in depth. The objective was to investigate, how far existing evaluation methods of the incremental hole-drilling method that are only valid for residual stress analysis of homogenous material states can be applied to thick film systems with coating thicknesses between 50 μm and 1000 μm and to point out the application limits for these already existing methods. A systematic Finite Element (FE) study was carried out for coating systems with an axisymmetric residual stress state σ₁?=?σ₂. It is shown that conventional evaluation methods developed for homogeneous, non-layered material states can be successfully applied for a stress evaluation in the substrate and the coating for small and for sufficiently large coating thicknesses, respectively, regardless of the type of evaluation algorithm used i.e. the differential or the integral method. The same accounts for material combinations that have a Young’s modulus ratio close to one, between 0.8 and 1.2. The studies indicated that outside the given ranges case specific calibration must be applied to calculate reliable results. Further, calibration data were determined case specifically for a selected model coating system. The accuracy of a residual stress determination using these case specific calibration data was examined and the sensitivity of the evaluation with respect to an accurate knowledge of the boundary conditions of the coating system i.e. the coating thickness and the Young modulus was studied systematically. Finally, the calibration data were applied on a thermally sprayed aluminium coating on a steel substrate analysis and the results for using the incremental hole drilling method were compared to results from X-ray stress analysis.     

Slitting Measurement of Residual Hoop Stresses Through the Wall-Thickness of a Filament Wound Composite Ring

The slitting method was used to determine residual hoop stress profile along the thickness of a filament wound carbon/epoxy ring. The method involves measuring strains at the inner surface of the ring, while a narrow axial slit is cut progressively from the outer surface. In order to calculate the residual hoop stress profile over the entire ring thickness, pulse method was used, which assumes that stress in each depth increment is uniform. Besides, Tikhonov regularization was employed to stabilize the stress results and reduce its sensitivity to strain measurement errors. Regarding the fact that Tikhonov regularization is not appropriate for computing solutions with discontinuities, pulse method coupled with Tikhonov regularization was used separately for each layer of the composite ring.     

Incremental Computation Technique for Residual Stress Calculations Using the Integral Method

The Integral Method for determining residual stresses involves making surface deformation measurements within a sequence of small increments of material removal depth. Typically, the associated matrix equation for solving the residual stresses within each depth increment is ill-conditioned. The resulting error sensitivity of the residual stress evaluation makes it essential that data measurement errors are minimized and that the residual stress solution method be as stable as possible. These two issues are addressed in this paper. The proposed method involves using incremental deformation data instead of the total deformation data that are conventionally used. The technique is illustrated using an example ESPI hole-drilling measurement.     

Incremental Hole Drilling for Residual Stress Analysis of Thin Walled Components with Regard to Plasticity Effects

The incremental hole-drilling method is widely used in residual stress depth distribution analysis. However, two specific difficulties with the generalization of the incremental method exist, including the consideration of the sample thickness and residual stress states close to the local material’s yield strength. The stress concentration effect of the hole can lead to plastic deformation in the vicinity of the hole, which results in an overestimation of residual stresses. Typically, the effect of the component’s thickness and the plasticity effects are analyzed separately and correction approaches are proposed. In the current paper, we analyze the combined effects of plasticity and thickness on residual stress analysis using the incremental hole-drilling method. A systematic study was performed on steel samples with (i) isotropic and (ii) anisotropic elastic and elasto-plastic material behavior with varying thicknesses ranging between 1 mm and 4 mm. Electronic speckle pattern interferometry (ESPI) hole-drilling experiments were conducted on beam samples loaded using a 4-point bending fixture. Finite element simulations were conducted to gain insight into the effects of incremental hole-drilling. The results indicate that reducing the component’s thickness increases the plastic deformation in the vicinity of the hole and results in significant stress deviations. Thin components bend during hole-drilling as a result of the loss of stiffness, which amplifies the plasticity effect.     

Thermal Stress Measurement in Continuous Welded Rails Using the Hole-Drilling Method

The absence of expansion joints in Continuous Welded Rail has created the need for the railroad industry to determine the in-situ thermal stress levels for rail buckling and breakage prevention. This paper explores the hole-drilling method as a possible solution to this problem. A new set of calibration coefficients to compute the stress field relieved by fine hole depth increments required by the high strength steel was determined. The new calibration coefficients were experimentally validated on an aluminum plate subjected to a known uniaxial load. The thermal stress levels of constrained rails were estimated after compensation for the residual stress components, based on statistical relationships developed experimentally between the longitudinal and the vertical residual stresses. The results showed that the hole-drilling procedure, with appropriate calibration coefficients and residual stress compensation, can estimate the in-situ rail thermal stresses with an expected accuracy that is within the industry acceptable levels.     

Intermethod Comparison and Evaluation of Measured Near Surface Residual Stress in Milled Aluminum

Background

While near surface residual stress (NSRS) from milling is a driver for distortion in aluminum parts there are few studies that directly compare available techniques for NSRS measurement.

Objective

We report application and assessment of four different techniques for evaluating residual stress versus depth in milled aluminum parts.

Methods

The four techniques are: hole-drilling, slotting, cos(α) x-ray diffraction (XRD), and sin²(ψ) XRD, all including incremental material removal to produce a stress versus depth profile. The milled aluminum parts are cut from stress-relieved plate, AA7050-T7451, with a range of table and tool speeds used to mill a large flat surface in several samples. NSRS measurements are made at specified locations on each sample.

Results

Resulting data show that NSRS from three techniques are in general agreement: hole-drilling, slotting, and sin²(ψ) XRD. At shallow depths (<?0.03 mm), sin²(ψ) XRD data have the best repeatability (<?15 MPa), but at larger depths (>?0.04 mm) hole-drilling and slotting have the best repeatability (<?10 MPa). NSRS data from cos(α) XRD differ from data provided by other techniques and the data are less repeatable. NSRS data for different milling parameters show that the depth of NSRS increases with feed per tooth and is unaffected by cutting speed.

Conclusion

Hole-drilling, slotting, and sin²(ψ) XRD provided comparable results when assessing milling-induced near surface residual stress in aluminum. Combining a simple distortion test, comprising removal of a 1 mm thick wafer at the milled surface, with a companion stress analysis showed that NSRS data from hole-drilling are most consistent with milling-induced distortion.

     

Evaluation of the High-Speed Drilling Technique for the Incremental Hole-Drilling Method

The incremental hole-drilling method is frequently used for residual stress depth distribution analyses, due to its fast and economical experimental execution. Depending on the planned use of the component, the drilled hole that is made to measure the residual stress can often be repaired or ignored if it does not affect the intended use of the part. Nevertheless an important experimental issue and assumption is the introduction of an ideal cylindrical hole into the component without additional plastic deformation. Although high-speed drilling is well established the consequences of the resulting hole geometries compared to ideal assumptions are not well known. Therefore, a detailed comparison between different bits and drilling techniques was carried out and is discussed in this paper in order to detect the best experimental conditions and to find out reasons especially for the lack of accuracy of the hole-drilling method for the first increments close to the specimens surface. It comes out that the orbital drilling with common used six-blade bits results in the best compromise of an ideal cylindrical hole and centricity to the center of the strain gage rosette. In the case of conventional drilling the hole geometry differs from the ideal one if six-blade bits were used due to the influence of chamfers at the cutting edges and a non 180° plane end face and also in the case of a two-blade bit due to a non 180° plane end face and the tendency to more eccentric holes. Diamond bits cannot be recommended under all tested conditions due to their geometrical undefined shape.     

整体化复合材料结构残余应力实验研究

通过钻孔法测试了T型整体化复合材料结构件在不同固化工艺方案下的残余应力,并研究了多墙类加筋壁板的腹板和蒙皮的残余应力分布,以及不同钻孔深度对结构件内部残余应力测试结果的影响。研究结果表明:共固化方式下产生的残余应力要小于胶结共固化方式下的残余应力。     

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     

A general method for obtaining shear stress and normal stress functions from parallel disk rheometry data

The problems of converting the torque and normal force versus rim shear rate data generated by parallel disk rheometers into shear stress and normal stress difference as functions of shear rate are formulated as two independent integral equations of the first kind. Tikhonov regularization is used to obtain approximate solutions of these equations. This way of handling parallel disk rheometer data has the advantage that it is independent of the rheological constitutive equation and noise amplification is kept under control by the user-specified parameter in Tikhonov regularization. If the fluid under test exhibits a yield stress, Tikhonov regularization computation will simultaneously give an estimate of the yield stress. The performance of this method is demonstrated by applying it to a number of data sets taken from the published literature and to laboratory measurements conducted specifically for this investigation.     

复合材料层合板粘弹性固化残余应力分析

基于Ｓｃｈａｐｅｒｙ积分型粘弹性本构关系，推导了考虑横向剪切效应的复合材料层合板线性热粘弹性有限元分析列式，对层合板的粘弹性响应和加工成型过程中的残余应力进行了分析，给出一些有意义的结果     

Comparison of residual-stress variation with depth-analysis techniques for the hole-drilling method

Numerous data-analysis techniques have been developed to determine residual-stress information from strain data obtained from the hole-drilling method. The most commonly used technique for data analysis was developed by Rendler and Vigness (which forms the basis of the standard described in ASTM E837-85). A numerical development which was a model of the hole-drilling procedure has been used to determine stress variation with depth. A rigorous finite-element method to specifically analyze stresses in discrete hole increments has been developed. To evaluate these data-analysis techniques, three different computer-simulated stress fields are compared. The stress fields include a uniaxial stress that is constant with depth, a bending stress that varies linearly with depth, and a subsurface stress reversal. (The basis for this comparison is a finite-element developed technique. Its accuracy will be discussed later.) All data-analysis techniques showed excellent agreement for the uniaxial stress constant with depth test case. However, for the other two stress fields, significant discrepancies were apparent. Results are compared and discussed.     

复合材料层合板的低速冲击损伤及其剩余压缩强度研究

本文采用理论和实验方法研究了复合材料层合板的低速冲地及其剩余压缩强度。文中利用有限元方法和能量转换原理计算了层合板受到低速冲击的受载最危险状态，以及此时的应力分布；并用Ｔｓａｉ－Ｗｕ张量准则判断损伤情况，对产生损伤的单元进行相应的刚度折减，且作重复计算直至不产生新的损伤为止；最后，对受冲击的层合板还进行剩余压缩强度计算。在实验中，采用激光全息无损检测法测量了层合板的冲击损伤，并对受冲击的层合板进行     

Hole-drilling method using grating rosette and Moiré interferometry

The hole-drilling method is one of the most wellknown methods for measuring residual stresses. To identify unknown plane stresses in a specimen, a circular hole is first drilled in the infinite plate under plane stress, then the strains resulting from the hole drilling is measured. The strains may be acquired from interpreting the Moire signature around the hole. In crossed grating Moire interferometry, the horizontal and vertical displacement fields （u and v） can be obtained to determinate two strain fields and one shearing strain field. In this paper, by means of Moire interferometry and three directions grating （grating rosette） developed by the authors, three displacement fields （u, v and s） are obtained to acquire three strain fields. As a practical application, the hole-drilling method is adopted to measure the relief strains for aluminum and fiber reinforced composite. It is a step by step method; in each step a single laminate or equivalent depth is drilled to find some relationships between the drilling depth and the residual strains relieved in the fiber reinforced composite materials.     

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.     

Improved Calibration Coefficients for the Hole-Drilling Method Considering the Influence of the Poisson Ratio

For residual stress analyses with the incremental hole-drilling method adequate evaluation formalisms in order to transform the measured strains into stresses are required. The Integral Method is the most important theory used for analyses of nonlinear residual stress depth distributions. It is based on a calibration, which is carried out by Finite-Element-Analyses. For the sake of simplicity the used numerical models often represent an ideally cylindrical hole and ideal elastic material behavior with fixed elastic constants. The adaption of the calibration coefficients from the numerical simulations to the real experimental state is often performed by simple correction factors or is ignored completely. The following investigation highlights the influence of the Poisson ratio on the calibration coefficients for the most commonly used strain gage rosettes geometries, which are standardized by ASTME837-08. It comes out that the application of existing simple correction factors is only valid within a small range and better approximations can be obtained by alternative strategies.     

Measurement of residual stress in the weld overlay piping components

In general industry, especially in the nuclear industry, welding overlay repair is an important repair method mainly used to rebuild piping systems suffering from intergranular stress-corrosion cracking (IGSCC).The pipe surface is mechanically ground to obtain a smooth surface after the welding overlay repair. A better understanding of the effect of repair and grinding processes on the residual stresses at the surface of weld overlay is required. To obtain this understanding, it is necessary to measure directly the distribution of residual stresses on the specimen. It is expected that compressive residual stress should be induced at the inner wall surface of the pipe for prevention of IGSCC.The performance evaluation of welding overlay repair relies on whether or not the level and characteristic of the residual stress can be measured accurately. In this study, the hole-drilling strain-gage method, using the incremental drilling technique, was adopted to estimate the residual stresses on the inner and outer walls of the weld overlay pipe. The experimental results indicate that the residual stress at the pipe inner surface is compressive while that of the outer surface is tensile. Also, it is found that the depth affected by grinding is about 1.016 mm.     

Micron-Scale Residual Stress Measurement by Micro-Hole Drilling and Digital Image Correlation

This paper reports a new technique, namely the incremental micro-hole-drilling method (IμHD) for mapping in-plane residual or applied stresses incrementally as a function of depth at the micron-scale laterally and the sub-micron scale depth-wise. Analogous to its macroscale counterpart, it is applicable either to crystalline or amorphous materials, but at the sub-micron scale. Our method involves micro-hole milling using the focused ion beam (FIB) of a dual beam FEGSEM/FIB microscope. The resulting surface displacements are recorded by digital image correlation of SEM images recorded during milling. The displacement fields recorded around the hole are used to reconstruct the stress profile as a function of depth. In this way residual stresses have been characterized around a drilled hole of 1.8microns. diameter, enabling the profiling of the stress variation at the sub-micron scale to a depth of 1.8 microns. The new method is used to determine the near surface stresses in a (peened) surface-severe-plastically-deformed (S²PD) Zr₅₀Cu₄₀Al₁₀ (in atomic percent, at.%) bulk metallic glass bar. In plane principal stresses of -800 MPa ± 90 MPa and −600 MPa ± 90 MPa were measured, the maximum compressive stress being oriented 15° to the axis of the bar.