A Study of the Residual Stress Distribution in an Autofrettaged, Thick-Walled Cylinder With Cross-Bore

It may be necessary to provide a radial opening such as gas evacuator holes, or an opening to operate the unlocking of the bolt mechanism by means of exhaust gases, in a gun barrel, which is a thick walled cylinder. A three dimensional finite element analysis has been performed to evaluate the effect of introducing a radial cross-bore in an autofrettaged thick-walled cylinder. From the analysis of the cross-bored autofrettaged cylinder, it was observed that there is a severe localized change in the residual stress profile in the vicinity of the cross-bore. The residual circumferential stress increases in compression at the bore. Similarly it increases in tension at the outer diameter, thus making the outer diameter more vulnerable to fatigue failure or crack initiation under stresses arising as a result of firing. Analyses were also performed by varying the cross-bore diameter and it was observed that, by increasing the diameter of the radial hole, the residual circumferential stress at the bore reduces, while it increases at the outer diameter, with an increase in the cross bore diameter. The re-pressurization pressure of an autofrettaged cylinder with radial cross-bore was found to be approximately 65 percent less than the actual autofrettage pressure in a particular case discussed in this paper. A comparison is also made with the residual stress field which would result if the cross-bore was machined before autofrettage.

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Numerical Analysis of the Effect of Machining on the Depth of Yield, Maximum Firing Pressure and Residual Stress Profile in an Autofrettaged Gun Tube

Journal of Pressure Vessel Technology ◽

10.1115/1.1593081 ◽

2003 ◽

Vol 125 (3) ◽

pp. 342-346 ◽

Cited By ~ 4

Author(s):

Amer Hameed ◽

R. D. Brown ◽

J. G. Hetherington

Keyword(s):

Residual Stress ◽

Finite Element ◽

Optimization Technique ◽

Circumferential Stress ◽

Element Model ◽

Stress Profile ◽

Residual Stress Field ◽

Element Analysis ◽

Residual Stress Profile ◽

Experimental Findings

A multi-linear kinematic, two dimensional finite element model incorporating Bauschinger effect, developed using ANSYS commercial software is used to determine the effect of machining both at the bore and at the outside diameter, on the depth of yield, maximum firing pressure and final residual stress field present in an autofrettaged gun tube. The model, which is in good agreement with experimental findings, clearly shows that the reduction in maximum compressive circumferential stress is more sensitive to internal machining than to external machining; the depth of yield remains stable and there is no movement of the elastic-plastic interface, relative to its location before material removal. If the internal machining removes material in which reverse yield has occurred, the maximum firing pressure is not affected. The finite element analysis supported by experimental evidence thus leads to an optimization technique for gun tube design.

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The Change in Overstrain Level Resulting From Machining of an Autofrettaged Thick-Walled Cylinder

Journal of Pressure Vessel Technology ◽

10.1115/1.556145 ◽

1999 ◽

Vol 122 (1) ◽

pp. 9-14 ◽

Cited By ~ 6

Author(s):

M. Perl

Keyword(s):

Residual Stress ◽

Stress Field ◽

Thermal Load ◽

Machining Process ◽

Residual Stress Field ◽

Element Analysis ◽

Gun Barrel ◽

Algebraic Expressions ◽

Walled Cylinder

An analytical model for predicting the level of autofrettage following either inner, outer, or combined machining of a gun barrel is developed based on Hill’s (Hill, R., 1950, The Mathematical Theory of Plasticity, Clarendon Press, Oxford, U.K.) solution for the autofrettage residual stress field. The analysis results in very simple algebraic expressions for the post-machining level of autofrettage in terms of the original level induced in the blank tube. In parallel, a finite element analysis of the machining process is performed in which the residual stress field is simulated by an equivalent thermal load. The numerical results are found to be in excellent agreement with the analytical ones. Thus, as an equivalent thermal load can always be determined, either analytically or numerically, for any other approximations to the residual stress field due to autofrettage (Perl, M., 1988, ASME J. Pressure Vessel Technol., 110, pp. 100–102), the foregoing methodology can be readily applied, enabling the determination of post-machining autofrettage level in these cases. [S0094-9930(00)00501-1]

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A Numerical Study on the Redistribution of Residual Stress After Machining

Volume 2: Advanced Manufacturing ◽

10.1115/imece2017-71199 ◽

2017 ◽

Author(s):

Kunyang Lin ◽

Wenhu Wang ◽

Ruisong Jiang ◽

Yifeng Xiong

Keyword(s):

Residual Stress ◽

Stress Field ◽

Residual Stresses ◽

Numerical Study ◽

Cutting Speed ◽

Machining Process ◽

Stress Profile ◽

Residual Stress Field ◽

Machining Processes ◽

Residual Stress Profile

Machining induced residual stresses have an important effect on the surface integrity. Effects of various factors on the distribution of residual stress profiles induced by different machining processes have been investigated by many researchers. However, the initial residual, as one of the important factor that affect the residual stress profile, is always been ignored. In this paper, the residual stress field induced by the quenching process is simulated by the FEM software as the initial condition. Then the initial residual stress field is used to study the residual stress redistribution after the machining process. The influence of initial stress on the stress formation is carried out illustrating with the mechanical and thermal loads during machining processes. The effects of cutting speed on the distribution of residual stress profile are also discussed. These results are helpful to understand how initial residual stresses are redistributed during machining better. Furthermore, the results in the numerical study can be used to explain the machining distortion problem caused by residual stress in the further work.

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Experimental/Modelling Study of Residual Stress in Al/SiCp Bent Bars by Synchrotron XRD and Slitting Eigenstrain Methods

Materials Science Forum ◽

10.4028/www.scientific.net/msf.571-572.277 ◽

2008 ◽

Vol 571-572 ◽

pp. 277-282 ◽

Cited By ~ 14

Author(s):

Xu Song ◽

Solène Chardonnet ◽

Giancarlo Savini ◽

Shu Yan Zhang ◽

Willem J.J. Vorster ◽

...

Keyword(s):

Residual Stress ◽

Residual Stresses ◽

Residual Strain ◽

Numerical Models ◽

Front Face ◽

Stress Profile ◽

X Ray Diffraction ◽

Element Analysis ◽

X Ray ◽

Residual Stress Profile

The aim of the study presented here was to evaluate the residual stresses present in a bar of aluminium alloy 2124-T1 matrix composite (MMC) reinforced with 25vol% particulate silicon carbide (SiCp) using X-ray diffraction and 3D profilometry (curvature measurement using Mitutoyo/Renishaw coordinate measurement machine) and comparing these results with numerical models of residual strain and stress profiles obtained by a simple inelastic bending model and Finite Element Analysis (FEA). The residual strain distribution was introduced into the test piece by plastic deformation in the 4-point bending configuration. At the first stage of this study the elasticplastic behaviour of the MMC was characterized under static and cyclic loading to obtain the material parameters, hardening proprieties and cyclic hysteresis loops. Subsequently, synchrotron Xray diffraction and CMM curvature measurements were performed to deduce the residual stress profile in the central section of the bar. The experimental data obtained from these measurements were used in the inelastic bending and FEA simulations. The specimens were then subjected to incremental slitting using EDM (electric discharge machining) with continuous back and front face strain gauge monitoring. The X-ray diffraction and incremental slitting results were then analysed using direct and inverse eigenstrain methods. Residual stresses plots obtained by different methods show good agreement with each other.

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Study of the Effect of Thickness on the Residual Stress Profile of a Cold Spray Coating by Finite Element Analysis

10.31399/asm.cp.itsc2021p0261 ◽

2021 ◽

Author(s):

Felipe Torres ◽

Ruben Fernandez

Keyword(s):

Residual Stress ◽

Finite Element Analysis ◽

Finite Element ◽

Cold Spray ◽

Spray Coating ◽

Stress Profile ◽

Element Analysis ◽

Residual Stress Profile ◽

Cold Spray Coating ◽

The Impact

Abstract The understanding of residual stress is of critical importance in the cold spray and thermal spray processes. It has a direct effect on the integrity of the coating related to the adhesion strength, fatigue life, and can lead to undesired effects such as the delamination of the coating. In cold spray, several investigations have evaluated the impact of the residual stress on the coatings, and it is generally accepted that cold spray coatings follow a similar profile to those obtained in the shot peening process. Although the measurement of residual stresses gives fundamental insight into the process, the estimation of such stresses considering the deposition of each layer by numerical methods has not been extensively studied. This work proposes a method for analyzing the evolution of residual stress on a cold spray coating, both on the coating and the substrate, as a function of the deposited layers, using Finite Element Analysis (FEA). The evolution of the residual stress profile with the coating thickness was obtained along the transverse direction. The results were compared to experimental and numerical data from previous studies. The influence of the deposition of each layer on the residual stress profile has been discussed.

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Residual Stresses around an Expanded Hole in an Aluminum Clad Sheet

Materials Science Forum ◽

10.4028/www.scientific.net/msf.490-491.41 ◽

2005 ◽

Vol 490-491 ◽

pp. 41-46 ◽

Cited By ~ 3

Author(s):

P. Matos ◽

Pedro Miguel Guimarães Pires Moreira ◽

J.C.P. Pina ◽

A. Morão Dias ◽

Paulo Manuel Salgado Tavares de Castro

Keyword(s):

Residual Stress ◽

Fatigue Cracks ◽

Numerical Data ◽

Stress Profile ◽

Detailed Knowledge ◽

X Ray Diffraction ◽

Element Analysis ◽

Residual Stress Profile ◽

Clad Sheet ◽

Numerical Tools

Cold working introduces a compressive stress field around rivet holes, reducing the tendency for fatigue cracks to initiate and grow under cyclic mechanical loading. As it is well known, for the accurate assessment of fatigue lifetimes a detailed knowledge of the residual stress profile is required. Powerful experimental and numerical tools are nowadays available for that purpose. In the present work both types of tools, X-ray diffraction and 3D Finite Element Analysis (FEA), were used in order to evaluate the residual stress profile. A comparison of experimental and numerical data is presented and discussed.

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Application of the Eigenstrain Theory to Predict Residual Stress around Curved Edges after Laser Shock Peening

Materials Science Forum ◽

10.4028/www.scientific.net/msf.768-769.185 ◽

2013 ◽

Vol 768-769 ◽

pp. 185-192 ◽

Cited By ~ 1

Author(s):

Stefano Coratella ◽

M. Burak Toparli ◽

Michael E. Fitzpatrick

Keyword(s):

Residual Stress ◽

Residual Stresses ◽

Laser Shock Peening ◽

Stress Profile ◽

Laser Shock ◽

Element Analysis ◽

Residual Stress Profile ◽

The Finite Element Analysis ◽

Treatment Technologies ◽

Shock Peening

Residual stresses play a fundamental role in mechanical engineering. They can be generated by manufacturing processes or introduced purposely by surface treatment technologies. One of the most recent technologies developed to introduce residual stresses is Laser Shock Peening. Since it is a relatively expensive technology, a fundamental role is played by the Finite Element Analysis approach to predict the final residual stress profile. The FEA approach consists of either direct simulation of the LSP process or the application of the eigenstrain approach. The application of the eigenstrain theory in predicting residual stresses after LSP treatment in curved edges is the subject of this research.

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Optimization Study of Post-Weld Heat Treatment for 12Cr1MoV Pipe Welded Joint

Metals ◽

10.3390/met11010127 ◽

2021 ◽

Vol 11 (1) ◽

pp. 127

Author(s):

Zichen Liu ◽

Xiaodong Hu ◽

Zhiwei Yang ◽

Bin Yang ◽

Jingkai Chen ◽

...

Keyword(s):

Heat Treatment ◽

Residual Stress ◽

Stress Reduction ◽

Simulation Method ◽

Post Weld Heat Treatment ◽

Residual Stress Field ◽

Element Analysis ◽

Tempering Treatment ◽

Temper Heat Treatment ◽

Weld Heat

In order to clarify the role of different post-weld heat treatment processes in the manufacturing process, welding tests, post-weld heat treatment tests, and finite element analysis (FEA) are carried out for 12C1MoV steel pipes. The simulated temperature field and residual stress field agree well with the measured results, which indicates that the simulation method is available. The influence of post-weld heat treatment process parameters on residual stress reduction results is further analyzed. It is found that the post weld dehydrogenation treatment could not release residual stress obviously. However, the residual stress can be relieved by 65% with tempering treatment. The stress relief effect of “post weld dehydrogenation treatment + temper heat treatment” is same with that of “temper heat treatment”. The higher the temperature, the greater the residual stress reduction, when the peak temperature is at 650–750 °C, especially for the stress concentration area. The longer holding time has no obvious positive effect on the reduction of residual stress.

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