Mapping Multiple Components of the Residual Stress Tensor in a Large P91 Steel Pipe Girth Weld Using a Single Contour Cut

The contour method is applied in an innovative manner to measure the distribution of hoop residual stress in a large martensitic-ferritic steel pipe containing a multi-pass girth weld. First, a novel one-step wire electro-discharge machining cut is conducted to divide the pipe lengthways into two halves. The deformation of the cut halves is then measured and analysed in a way that simultaneously gives maps of hoop stress across the wall thickness on both sides of the pipe and automatically accounts for through-thickness hoop bending effects and how they may vary along the pipe. Finally the contour method results are combined with X-ray diffraction residual stress measurements using the principle of superposition to determine the distribution of the axial and radial residual stresses in the pipe. It is thereby demonstrated how the distribution of three direct components of the residual stress tensor in a welded pipe can be readily determined using a “hybrid” contour measurement approach.     

A Novel Cutting Strategy for Measuring Two Components of Residual Stresses Using Slitting Method

An exact knowledge of residual stresses that exist within the engineering components is essential to maintain the structural integrity. All mechanical strain relief (MSR) techniques to measure residual stresses rely on removing a section of material that contains residual stresses. Therefore, these techniques are destructive as the integrity of the components is compromised. In slitting method, as a MSR technique, a slot with an increasing depth is introduced to the part incrementally that results in deformations. By measuring these deformations the residual stress component normal to the cut can be determined. Two orthogonal components of residual stresses were measured using the slitting method both experimentally and numerically. Different levels of residual stresses were induced into beam shaped specimens using quenching process at different temperatures. The experimental results were then compared with those numerically predicted. It was shown that while the first component of residual stress was being measured, its effect on the second direction that was normal to the first cut was inevitable. Finally, a new cutting configuration was proposed in which two components of residual stresses were measured simultaneously. The results of the proposed method indicated a good agreement with the conventional slitting.     

Repeatability of the Contour Method for Residual Stress Measurement

This paper describes the results of a residual stress measurement repeatability study using the contour method. The test specimen is an aluminum bar (cut from plate), with cross sectional dimensions of 50.8 mm?×?76.2 mm (2 in?×?3 in) with a length of 609.6 mm (24 in). There are two bars, one bar with high residual stresses and one bar with low residual stresses. The high residual stress configuration (±150 MPa) is in a quenched and over-aged condition (Al 7050-T74) and the low residual stress configuration (±20 MPa) is stress relieved by stretching (Al 7050-T7451). Five contour measurements were performed on each aluminum bar at the mid-length of successively smaller pieces. Typical contour method procedures are employed with careful clamping of the specimen, wire electric discharge machining (EDM) for the cut, laser surface profiling of the cut faces, surface profile fitting, and linear elastic stress analysis. The measurement results provide repeatability data for the contour method, and the difference in repeatability when measuring high or low magnitude stresses. The results show similar repeatability standard deviation for both samples, being less than 10 MPa over most of the cross section and somewhat larger, around 20 MPa, near the cross section edges. A comparison with published repeatability data for other residual stress measurement techniques (x-ray diffraction, incremental hole drilling, and slitting) shows that the contour method has a level of repeatability that is similar to, or better than, other techniques.     

Measuring Inaccessible Residual Stresses Using Multiple Methods and Superposition

The traditional contour method maps a single component of residual stress by cutting a body carefully in two and measuring the contour of the cut surface. The cut also exposes previously inaccessible regions of the body to residual stress measurement using a variety of other techniques, but the stresses have been changed by the relaxation after cutting. In this paper, it is shown that superposition of stresses measured post-cutting with results from the contour method analysis can determine the original (pre-cut) residual stresses. The general superposition theory using Bueckner’s principle is developed and limitations are discussed. The procedure is experimentally demonstrated by determining the triaxial residual stress state on a cross section plane. The 2024-T351 aluminum alloy test specimen was a disk plastically indented to produce multiaxial residual stresses. After cutting the disk in half, the stresses on the cut surface of one half were determined with X-ray diffraction and with hole drilling on the other half. To determine the original residual stresses, the measured surface stresses were superimposed with the change stress calculated by the contour method. Within uncertainty, the results agreed with neutron diffraction measurements taken on an uncut disk.     

Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

Experimental Mechanics - Background: While the contour method for residual stress assessment has developed rapidly, no published study documents its interlaboratory reproducibility. Objective: Here...     

Evaluation of Residual Stresses Induced by Robotized Hammer Peening by the Contour Method

Welded components suffer from high tensile residual stresses close to the weld beads. These stresses seem to be the origin of premature cracking which could result in a catastrophic rupture during operation and a reduction of the lifespan of these components. In this context, the Hydro-Québec’s Research Institute (IREQ) developed a technique of residual stresses relaxation by robotized hammer peening which makes it possible to release stresses close to surface and preserve the mechanical and dimensional properties of manufactured components. Robotized hammer peening was used to induce compressive residual stresses on initially stress free samples of austenitic stainless steel 304L. Hammer peening layers from one to nine were performed and the resulting residual stresses were evaluated thanks to the contour technique. Complete 2D residual stress fields on samples cross sections were obtained. The ability of hammer peening to relax residual stresses within welded plates was then quantified on austenitic stainless steel 304L plates welded with a 308 steel and hammer peened. These tests show the efficiency of hammer peening as a method to relax tensile residual stresses and induce compressive ones to a depth of a few millimetres. Process parameters were optimized such as the number of hammer peening layers to be applied to reduce processing time and maximization of the intensity and spatial distribution of the compressive residual stresses.     

Multi-Axial Contour Method for Mapping Residual Stresses in Continuously Processed Bodies

This paper describes a method for extending the capability of the contour method to allow for the measurement of spatially varying multi-axial residual stresses in prismatic, continuously processed bodies. Currently, the contour method is used to determine a 2D map of the residual stress normal to a plane. This work uses an approach similar to the contour method to quantify multiple components of eigenstrain in continuously processed bodies, which are used to calculate residual stress. The result of the measurement is an estimate of the full residual stress tensor at every point in the body. The approach is first outlined for a 2D body and the accuracy of the methodology is demonstrated for a representative case using a numerical experiment. Next, an extension to the 3D case is given and the accuracy is demonstrated for representative cases using numerical experiments. Finally, measurements are performed on a thin sheet of Ti-6Al-4V with a band of laser peening down the center (assumed to be 2D) and a thick laser peened plate of 316L stainless steel to show that the approach is valid under real experimental conditions.     

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.     

Correction to: Interlaboratory Reproducibility of Contour Method Data Analysis and Residual Stress Calculation

Experimental Mechanics - The original version of this article has been corrected to include authors middle initials in the author list. The details given in this correction are correct.     

On the Reconstitution Problem in the Multiple Time-Scale Method

Higher-order multiple-scale methods for general multiparameter mechanical systems are studied. The role played by the control and imperfection parameters in deriving the perturbative equations is highlighted. The definition of the codimension of the problem, borrowed from the bifurcation theory, is extended to general systems, excited either externally or parametrically. The concept of a reduced dynamical system is then invoked. Different approaches followed in the literature to deal with reconstituted amplitude equations are discussed, both in the search for steady-state solutions and in the analysis of stability. Four classes of methods are considered, based on the consistency or inconsistency of the approach, and on the completeness or incompleteness of the terms retained in the analysis. The four methods are critically compared and general conclusions drawn. Finally, three examples are illustrated to corroborate the findings and to show the quantitative differences between the various approaches.     

Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

Cutting-induced plasticity can lead to elevated uncertainties in residual stress measurements made by the contour method. In this study plasticity-induced stress errors are numerically evaluated for a benchmark edge-welded beam to understand the underlying mechanism. Welding and cutting are sequentially simulated by finite element models which have been validated by previous experimental results. It is found that a cutting direction normal to the symmetry plane of the residual stress distribution can lead to a substantially asymmetrical back-calculated stress distribution, owing to cutting-induced plasticity. In general, the stresses at sample edges are most susceptible to error, particularly when the sample is restrained during cutting. Inadequate clamping (far from the plane of cut) can lead to highly concentrated plastic deformation in local regions, and consequently the back-calculated stresses have exceptionally high values and gradients at these locations. Furthermore, the overall stress distribution is skewed towards the end-of-cut side. Adequate clamping (close to the plane of cut) minimises errors in back-calculated stress which becomes insensitive to the cutting direction. For minimal constraint (i.e. solely preventing rigid body motion), the plastic deformation is relatively smoothly distributed, and an optimal cutting direction (i.e. cutting from the base material towards the weld region in a direction that falls within the residual stress symmetry plane) is identified by evaluating the magnitude of stress errors. These findings suggest that cutting process information is important for the evaluation of potential plasticity-induced errors in contour method results, and that the cutting direction and clamping strategy can be optimised with an understanding of their effects on plasticity and hence the back-calculated stresses.     

Resolving Controversies in the Application of the Method of Multiple Scales and the Generalized Method of Averaging

I compare application of the method of multiple scales with reconstitution and the generalized method of averaging for determining higher-order approximations of three single-degree-of-freedom systems and a two-degree-of-freedom system. Three implementations of the method of multiple scales are considered, namely, application of the method to the system equations expressed as second-order equations, as first-order equations, and in complex-variable form. I show that all of these methods produce the same modulation equations.I address the problem of determining higher-order approximate solutions of the Duffing equation in the case of primary resonance. I show that the conclusions of Rahman and Burton that the method of multiple scales, the generalized method of averaging, and Lie series and transforms might lead to incorrect results, in that spurious solutions occur and the obtained frequency–response curves bear little resemblance to the actual response, is the result of their using parameter values for which the neglected terms are the same order as the retained terms. I show also that spurious solutions cannot be avoided, in general, in any consistent expansion and their presence does not constitute a limitation of the methods. In particular, I show that, for the Duffing equation, the second-order frequency–response equation does not possess spurious solutions for the case of hardening nonlinearity, but possesses spurious solutions for the case of softening nonlinearity. For sufficiently small nonlinearity, the spurious solutions are far removed from the actual response. But as the strength of the nonlinearity increases, these solutions move closer to the backbone and eventually distort it. This is not a drawback of the perturbation methods but an indication of an application of the analysis for parameter values outside the range of validity of the expansion.Also, I address the problem of obtaining non-Hamiltonian modulation equations in the application of the method of multiple scales to multi-degree-of-freedom Hamiltonian systems written as second-order equations in time and how this problem can be overcome by attacking the state-space form of the governing equations. Moreover, I show that application of a variation of the method of Rahman and Burton to multi-degree-of-freedom systems leads to results that do not agree with those obtained with the generalized method of averaging.Contributed by Prof. R.A. Ibrahim.     

Diffraction Assisted Image Correlation: A Novel Method for Measuring Three-Dimensional Deformation using Two-Dimensional Digital Image Correlation

Digital Image Correlation (DIC) provides a full-field non-contact optical method for accurate deformation measurement of materials, devices and structures. The measurement of three-dimensional (3D) deformation using DIC in general requires imaging with two cameras and a 3D-DIC code. In the present work, a new experimental technique, namely, Diffraction Assisted Image Correlation (DAIC) for 3D displacement measurement using a single camera and 2D-DIC algorithm is presented. A transmission diffraction grating is placed between the specimen and the camera, resulting in multiple images which are then used to obtain apparent in-plane displacements using 2D-DIC. The true in-plane and out-of-plane displacements of the specimen are obtained from the apparent in-plane displacements and the diffraction angle of the grating. The validity and accuracy of the DAIC method are demonstrated through 3D displacement measurement of a small thin membrane. This technique provides new avenues for performing 3D deformation measurements at small length scales and/or dynamic loading conditions.     

Measuring the mobility parameters of forwarders using GPS and CAN bus techniques

Use of a datalogger connected to the CAN bus of an 8-wheeled forwarder’s hydrostatic transmission permits measurement of the gross power on the driveline and the rotational velocity of the drive axle. The ground velocity and trajectory of the forwarder is monitored by the GPS technique. These data allow the total resistance force and wheel slip to be determined under different terrain conditions. In this paper the total resistance force is segregated into rolling, slope and winding resistances. The measuring system was tested in practice on an even tarmac surface and a gently sloping hard earth road, the number of input variables in the first tests having been reduced. It was found that the measuring accuracy permitted detection of about a half percent variation in slope inclination in the test lane. Tests on a figure of 8 track showed that the winding resistance can also be detected. It was concluded that the measuring technique is accurate enough for terramechanical research and practicable under real forestry conditions.     

Measuring the elongation viscosity of lyocell using a semi-hyperbolic die

The lyocell process involves dry jet—wet spinning of a solution of cellulose in N-methyl morpholine oxide monohydrate. Measurement of the elongation viscosity of lyocell is important for the design and optimization of the lyocell process. We present a useful method for the determination of the elongation viscosity of lyocell by using a combination of experimental measurements on a semi-hyperbolic die and viscoelastic simulations.     

转台测角系统标定方法的研究

本文提出一种高精度转台测角系统标定的新方法，该方法以光电自准直仪作为标定基准，用齿盘、多面棱镜作角度给定，转台工作在速率状态下，自动完成高精度转台测角系统标定任务，给出标定精度和误差曲线。该方法避免了人为因素造成的测量和计算误差，使标定过程更加快捷、准确、可靠。     

Measuring evaporation of micro-fuel droplets using magnified DIH and DPIV

This paper details the use of magnified digital in-line holography (MDIH) and digital particle image velocimetry (DPIV) to measure the evaporation rates of fuel micro-droplets undergoing heating. The technique can be used to measure instantaneous evaporation along an individual droplet trajectory, or if applied to a series of droplets, the average evaporation over a number of successive measurement locations. The advantage of this technique over traditional optical techniques is greater spatial resolution and depth of field for the high magnification factors used. An application of the technique to the evaporation measurement of diesel fuel droplets ranging from 10 to 90 μm is presented. Results reveal that similar to larger droplets, temperature plays the dominant role in evaporation processes, with little sensitivity to initial droplet size found for a peak reactor temperature of 660 K.