Effect of Friction on Residual Stress Distribution Induced by Split Sleeve Cold Expansion Process

Expansion Process ◽

Cold Expansion ◽

Abstract Residual Stress distribution and parametric influence of friction are studied for the split sleeve cold expanded holes in Al 2024 T351 alloy, by developing a three-dimensional finite element model of the process. Fastener holes in the alloy are necessary for the manufacturing process, but they create a potential area for stress concentration, which eventually leads to fatigue under cyclic loading. Beneficial compressive residual stress distribution as a result of the split sleeve cold expansion process provides retardation against crack initiation and propagation at the critical zones near hole edges. In this parametric study, the influence of friction between contact surfaces of the split sleeve and mandrel is numerically investigated. Hole reaming process after split sleeve cold expansion is often not discussed. Without this post-processing procedure, split sleeve cold expansion is incomplete in practice, and its purpose of providing better fatigue performance is invalidated. This study presents results and an overview of the significance of friction with the consideration of the postprocessing of split sleeve cold expansion. The numerical results show that with increasing friction coefficient, compressive residual stress reduces significantly at the mandrel entry side, which makes the hole edge more vulnerable to fatigue. The different aspects of finite element modeling approaches are also discussed to present the accuracy of the prediction. Experimental residual stress observation or visual validation is expensive and time-consuming. So better numerical prediction with the transparency of the analysis design can provide critical information on the process.

Three Dimensional Finite Element Analysis of a Split-Sleeve Cold Expansion Process

Journal of Engineering Materials and Technology ◽

10.1115/1.3120392 ◽

2009 ◽

Vol 131 (3) ◽

Cited By ~ 25

Author(s):

S. Ismonov ◽

S. R. Daniewicz ◽

J. C. Newman ◽

M. R. Hill ◽

M. R. Urban

Keyword(s):

Residual Stress ◽

Finite Element ◽

Three Dimensional ◽

Element Model ◽

Residual Stress Field ◽

Expansion Process ◽

Element Analysis ◽

Cold Expansion ◽

A cold expansion process is used to prolong the fatigue life of a structure under cyclic loadings. The process produces a beneficial compressive residual stress zone in the hole vicinity, which retards the initiation and propagation of the crack at the hole edge. In this study, a three-dimensional finite element model of the split-sleeve cold expansion process was developed to predict the resulting residual stress field. A thin rectangular aluminum sheet with a centrally located hole was considered. A rigid mandrel and an elastic steel split sleeve were explicitly modeled with the appropriate contact elements at the interfaces between the mandrel, the sleeve, and the hole. Geometrical and material nonlinearities were included. The simulation results were compared with experimental measurements of the residual stress. The influence of friction and the prescribed boundary conditions for the sheet were studied. Differences between the split-sleeve- and the non-split-sleeve model solutions are discussed.

Effect of cold expansion on fatigue life of double lap structure

Xibei Gongye Daxue Xuebao/Journal of Northwestern Polytechnical University ◽

10.1051/jnwpu/20213910189 ◽

2021 ◽

Vol 39 (1) ◽

pp. 189-196

Author(s):

Hang Peng ◽

Jianbo Qin ◽

Tianjiao Zhao

Keyword(s):

Residual Stress ◽

Finite Element ◽

Fatigue Life ◽

Stress Distribution ◽

Simulation Analysis ◽

Element Model ◽

Cold Expansion ◽

Before And After ◽

Hole Making

The finite element simulation analysis was used to determine the weak parts of the fatigue life of a double lap structure, for which the cold expansion finite element model was established. The effect of the cold expansion of slotted bushings on the residual stress distribution around the hole of the double lap structure under different interferences was deeply studied, and the optimal interference amount was determined to be 2.5%. The effect of reaming on the residual stress distribution around the hole was studied. The residual stress distribution around the edge of the hole under actual loading conditions before and after cold expansion was compared to provide a theoretical analysis basis for extending the fatigue life of the specimen after cold expansion. The China-made and free- forged 7A85 aluminum alloy specimen was used to obtain the fatigue life and DFR value of the double lap structure after ordinary hole making and the cold expansion of slotted bushing. The results show that the fatigue life under 95% confidence and 95% reliability after cold expansion strengthening increases by about 49% and that the tested DFR value increases by about 9.8%.

Measurement of the three-dimensional residual stress distribution around split-sleeve cold-expanded holes

The Journal of Strain Analysis for Engineering Design ◽

10.1243/03093247v316413 ◽

1996 ◽

Vol 31 (6) ◽

pp. 413-421 ◽

Cited By ~ 48

Author(s):

A T Özdemir ◽

L Edwards

Keyword(s):

Residual Stress ◽

Stress Distribution ◽

Plate Thickness ◽

Three Dimensional ◽

Expansion Process ◽

Cold Expansion ◽

Civil Aircraft ◽

Hoop Stresses ◽

Fatigue Endurance

Cold expansion of fastener holes is an increasingly common way of improving the fatigue endurance of airframes. Although a number of methods of cold expansion are possible, the split-sleeve cold-expansion process is the most widely accepted and is widely used in the repair and manufacture stages of both military and civil aircraft. In the present work, the residual stress distribution around split-sleeve cold-expanded holes has been measured as a function of both position through the plate thickness and around the hole through novel use of the Sachs method. It is found that the residual hoop stresses being generated at the mid-thickness of the plate at orientation 90° from the position of the split in the expansion sleeve. It is suggested that this variation must be taken into account both in the implementation of the technology and in any potential model used for the prediction of fatigue life of cold-expanded holes.

Numerical Study of Welding Sequence on the Residual Stress Field in a Thick-Walled Tee Joint

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.219-220.1211 ◽

2011 ◽

Vol 219-220 ◽

pp. 1211-1214

Author(s):

Wei Jiang

Keyword(s):

Residual Stress ◽

Finite Element ◽

Numerical Study ◽

Three Dimensional ◽

Element Model ◽

Residual Stress Field ◽

Factors Affecting ◽

Welding Sequence ◽

Welding Sequences ◽

Finite element simulation is an efficient method for studying factors affecting weld-induced residual stress distributions. In this paper, a validated three-dimensional finite element model consisting of sequentially coupled thermal and structural analyses was developed. Three possible symmetrical welding sequences, i.e. one-welder, two-welder and four-welder sequence, which were perceived to generate the least distortion in actual welding circumstances, were proposed and their influences on the residual stress fields in a thick-walled tee joint were investigated. Appropriate conclusions and recommendations regarding welding sequences are presented.

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

Residual stress distribution in built-in beams

10.1177/1464420720958617 ◽

2020 ◽

pp. 146442072095861

Author(s):

FA de Castro ◽

Paulo P Kenedi ◽

LL Vignoli ◽

I I T Riagusoff

Keyword(s):

Residual Stress ◽

Finite Element ◽

Stress Distribution ◽

Cross Section ◽

Cross Sections ◽

Element Model ◽

Concentrated Load ◽

Load Growth ◽

Final Failure

Metallic hyperstatic structures, like beams, submitted to excessive loads, do not fail completely before fully yielding in more than one cross section. Indeed, for built-in beams, three cross sections must be fully yielded before the final failure can occur. So, modeling the evolution of the cross-section residual stress distribution is an important subject that should be addressed to guarantee the stress analysis modeling correctness. This paper analyses the residual stress distribution evolution, in critical cross sections, of built-in beams during a transversal concentrated load growth, until the final failure through hinges formation. A finite element model is also presented. The results show good matches with the numerical model, used as a reference.

A Three-Dimensional Finite Element Evaluation of a Destructive Experimental Method for Determining Through-Thickness Residual Stresses in Girth Welded Pipes

Journal of Engineering Materials and Technology ◽

10.1115/1.3225866 ◽

1986 ◽

Vol 108 (2) ◽

pp. 99-106 ◽

Cited By ~ 17

Author(s):

E. F. Rybicki ◽

J. R. Shadley

Keyword(s):

Residual Stress ◽

Finite Element ◽

Experimental Method ◽

Three Dimensional ◽

Element Model ◽

Stress Distributions ◽

Reference Stress ◽

Improvement Process ◽

The accuracy of a destructive, experimental method for the evaluation of through-thickness residual stress distributions is investigated. The application of the method is to a welded pipe that has been subjected to a residual stress improvement process. The residual stress improvement process introduces gradients in the stress distribution. The question of interest is how well the back-computation method used to interpret the experimental data represents the residual stress distribution for this type of stress profile. To address this question, a finite element model was used to provide a reference stress solution for comparison with the back-computation results of the experimental method. Three-dimensional finite element stress analyses were also conducted to simulate the cutting steps of the destructive laboratory procedure. The residual stress distributions obtained by the back-computation procedure were then compared with the reference stress solutions provided by the finite element model. The comparisons show agreement and indicate that good results can be expected from the experimental method when it is applied to a pipe that has been subjected to a residual stress improvement process, provided that the axial gradient of stress is not too large.

Effect of Friction on Residual Stress Distribution Induced by Split Sleeve Cold Expansion Process

10.1115/1.0004160v ◽

2021 ◽

Author(s):

Mithun Kumar Dey ◽

Dave Kim ◽

Hua Tan

Keyword(s):

Residual Stress ◽

Stress Distribution ◽

Expansion Process ◽

Cold Expansion

A Study on Construction Three-Dimensional Nonlinear Finite Element Model and Stress Distribution Analysis of Anterior Cruciate Ligament

Journal of Biomechanical Engineering ◽

10.1115/1.4000167 ◽

2009 ◽

Vol 131 (12) ◽

Cited By ~ 16

Author(s):

Feng Xie ◽

Liu Yang ◽

Lin Guo ◽

Zhi-jun Wang ◽

Gang Dai

Keyword(s):

Finite Element ◽

Stress Distribution ◽

Knee Joint ◽

Finite Element Model ◽

Laser Scanning ◽

Cruciate Ligament ◽

Three Dimensional ◽

Element Model ◽

To establish a finite element model that reflects the geometric characteristics of the normal anterior cruciate ligament (ACL), explore the approaches to model knee joint ligaments and analyze the mechanics of the model. A healthy knee joint specimen was subjected to three-dimensional laser scanning, and then a three-dimensional finite element model for the normal ACL was established using three-dimensional finite element software. Based on the model, the loads of the ACL were simulated to analyze the stress-strain relationship and stress distribution of the ACL. Using the ABAQUS software, a three-dimensional finite element model was established. The whole model contained 22,125 nodes and 46,411 units. In terms of geometric similarity and mesh precision, this model was superior to previous finite element models for the ACL. Through the introduction of material properties, boundary conditions, and loads, finite elements were analyzed and computed successfully. The relationship between overall nodal forces and the displacement of the ACL under anterior loads of the tibia was determined. In addition, the nephogram of the ACL stress spatial distribution was obtained. A vivid, three-dimensional model of the knee joint was established rapidly by using reverse engineering technology and laser scanning. The three-dimensional finite element method can be used for the ACL biomechanics research. The method accurately simulated the ACL stress distribution with the tibia under anterior loads, and the computational results were of clinical significance.

Extruded upper first molar intrusion: Comparison between unilateral and bilateral miniscrew anchorage

Dental Press Journal of Orthodontics ◽

10.1590/2177-6709.23.1.063-070.oar ◽

2018 ◽

Vol 23 (1) ◽

pp. 63-70 ◽

Cited By ~ 3

Author(s):

Mari Miura Sugii ◽

Bruno de Castro Ferreira Barreto ◽

Waldemir Francisco Vieira-Júnior ◽

Katia Regina Izola Simone ◽

Ataís Bacchi ◽

...

Keyword(s):

Finite Element ◽

Stress Distribution ◽

Alveolar Bone ◽

Three Dimensional ◽

Root Apex ◽

Element Model ◽

Lower Probability ◽

Homogeneous Stress ◽

ABSTRACT Objective: The aim of his study was to evaluate the stress on tooth and alveolar bone caused by orthodontic intrusion forces in a supraerupted upper molar, by using a three-dimensional Finite Element Method (FEM). Methods: A superior maxillary segment was modeled in the software SolidWorks 2010 (SolidWorks Corporation, Waltham, MA, USA) containing: cortical and cancellous bone, supraerupted first molar, periodontal tissue and orthodontic components. A finite element model has simulated intrusion forces of 4N onto a tooth, directed to different mini-screw locations. Three different intrusion mechanics vectors were simulated: anchoring on a buccal mini-implant; anchoring on a palatal mini-implant and the association of both anchorage systems. All analyses were performed considering the minimum principal stress and total deformation. Qualitative analyses exhibited stress distribution by color maps. Quantitative analysis was performed with a specific software for reading and solving numerical equations (ANSYS Workbench 14, Ansys, Canonsburg, Pennsylvania, USA). Results: Intrusion forces applied from both sides (buccal and palatal) resulted in a more homogeneous stress distribution; no high peak of stress was detected and it has allowed a vertical resultant movement. Buccal or palatal single-sided forces resulted in concentrated stress zones with higher values and tooth tipping to respective force side. Conclusion: Unilateral forces promoted higher stress in root apex and higher dental tipping. The bilateral forces promoted better distribution without evidence of dental tipping. Bilateral intrusion technique suggested lower probability of root apex resorption.

Finite Element Analysis for the Mega Columns for XRL West Kowloon Terminus

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.405-408.1139 ◽

2013 ◽

Vol 405-408 ◽

pp. 1139-1143

Author(s):

Wei Su ◽

Ying Sun ◽

Shi Qing Huang ◽

Ren Huai Liu

Keyword(s):

Finite Element ◽

Stress Distribution ◽

Parametric Design ◽

Three Dimensional ◽

Element Model ◽

Von Mises Stress ◽

Element Analysis ◽

Von Mises ◽

Using ANSYS parametric design language, a three-dimensional finite element model is developed to analyze the stress distribution and the strength of the mega columns for XRL West Kowloon Terminus. The detailed von Mises stress distribution in each column, vertical stiffener plates and the diaphragm plates is obtained. From the analysis, the phenomenon of stress concentration is obvious in both upper and lower diaphragm plates. The local value of von Mises stress in them is higher than the yield stress value, which must be avoided by more detailed local structural design.