Residual stress field and reduction of stress intensity factors in cold-worked holes

Closed-form and semi-analytical solutions are obtained for the residual stress distributions in a plate caused by pressure acting on a central circular hole, representing the cold-work process. The material is elastic–perfectly plastic. Both Tresca and von Mises yield criteria are used and the corresponding residual stress distributions are compared. The relation between the dimension of the plastic zone and the value of internal pressure is presented. The relation between the magnitude of the residual stresses and the remote uniform tensile stress required to open symmetrical radial cracks is also presented. The reduction of the stress intensity factors of cracked open and riveted holes as a function of the internal pressure applied (or mandrel radial displacement) is investigated using numerical models for both an elastic–perfectly plastic material and for an Al 2024-T3 Alclad aluminum alloy.