Measurement and Prediction of Machining Induced Redistribution of Residual Stress in the Aluminium Alloy 7449

The residual stress distributions in two 7449 aluminium alloy rectilinear blocks have been determined using neutron diffraction. Heat treatment included cold water immersion quenching and a period of precipitation hardening. Quenching induced very high magnitude residual stresses into the two blocks. One block was measured in this condition while the other was incrementally machined by milling to half thickness. Neutron diffraction measurements were made on the milled half thickness block at equivalent locations to the unmachined block. This permitted through thickness measurements from both blocks to be compared, revealing the redistribution of residual stresses induced by machining. A square cross section post in the centre of the machined face was left to act as a stress free reference sample. The distortions arising on the face opposite to that being milled were measured using a co-ordinate measuring machine. The residual stresses and distortion arising in the blocks have been compared to finite element analysis prediction and found to generally agree. Material removal only caused distortion and the residual stresses to redistribute; there was no stress relaxation evident.     

Mixing enhancement in a multi-stream injection nozzle

We present quantitative analysis of image sequences of multi-stream injection nozzle flows with several different injection geometries in an experiment simulating mixing in a chemical oxygen-iodine laser. To visualize mixing, image sequences were acquired with planar laser-induced fluorescence (PLIF) in iodine that was injected into the main flow. The injection nozzle consisted of a slot, ejector, and injector block, with rows of ejector and injector holes along the slot length. The ejector flow exits in an underexpanded state so that upon expanding it forces the slot and injector flows together to enhance mixing. For this study, the diameter and geometry of ejector holes were varied to assess their effect on mixing. Two configurations of ejector holes were used, each with two different diameters for a total of four cases with data collected at downstream stations. We carry out a quantitative mixing analysis for these configurations, using two methods to quantify the mixing. The first method considers the statistics of the PLIF image intensity histograms, which are bimodal for poorly-mixed flows and have a single peak in well-mixed flows. The second method quantifies the properties of the mixing interface. Our analysis shows that two injection schemes significantly enhance mixing by stretching the mixing interface.     

On a stochastic nonlinear equation arising from 1D integro-differential scalar conservation laws

In this paper we study the initial problem for a stochastic nonlinear equation arising from 1D integro-differential scalar conservation laws. The equation is driven by Lévy space-time white noise in the following form:

(t_∂−A)u+x_∂q(u)=f(u)+g(u)Ft,x     

A method for reconstruction of residual stress fields from measurements made in an incompatible region

A method is introduced by which the complete state of residual stress in an elastic body may be inferred from a limited set of experimental measurements. Two techniques for carrying out this reconstruction using finite element analysis are compared and it is shown that for exact reconstruction of the stress field via this method, the stress field must be measured over all eigenstrain-containing regions of the object. The effects of error and incompleteness in the measured part of the stress field on the subsequent analysis are investigated in a series of numerical experiments using synthetic measurement data based on the NeT TG1 round-robin weld specimen. It is hence shown that accurate residual stress field reconstruction is possible using measurement data of a quality achievable using current experimental techniques.     

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.     

Photoelastic Investigation of Slippage in Shrink-Fit Assemblies

The development of torque-induced shear stresses in the presence of slippage, and the residual stresses remaining after torque-induced slippage, are analysed using frozen-stress photoelasticity. Shaft/ring specimens were manufactured from epoxy photoelastic material and were assembled by shrink-fitting prior to being loaded under various regimes, notably the application and release of a torque load. The interface pressure was predicted from Lamé thick cylinder theory, and was also estimated by fitting the Lamé model to the measured stress distributions. The distributions of interface shear stress were calculated from averaged photoelastic data, and compared with the results of a dislocation-based model and with a nonlinear finite element model. For a torque loaded specimen there was good agreement between experimental, theoretical and FE data. Another specimen was loaded in torque then unloaded, with results showing the expected features of slippage and residual stress.