A new cantilever technique reveals spatial distributions of residual stresses in near-surface structures

2008 ◽  
Vol 59 (5) ◽  
pp. 503-506 ◽  
Author(s):  
S. Massl ◽  
J. Keckes ◽  
R. Pippan
Keyword(s):  
Residual Stresses ◽  
Surface Structures ◽  
Spatial Distributions ◽  
Near Surface

scholarly journals Shear cutting induced residual stresses in involute gears and resulting tooth root bending strength of a fineblanked gear

2021 ◽  
Author(s):  
Daniel Müller ◽  
Jens Stahl ◽  
Anian Nürnberger ◽  
Roland Golle ◽  
Thomas Tobie ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Carrying Capacity ◽  
Bending Strength ◽  
Tooth Root ◽  
Load Carrying Capacity ◽  
Near Surface ◽  
Load Carrying ◽  
Involute Gears ◽  
Cut Surface

AbstractThe manufacturing of case-hardened gears usually consists of several complex and expensive steps to ensure high load carrying capacity. The load carrying capacity for the main fatigue failure modes pitting and tooth root breakage can be increased significantly by increasing the near surface compressive residual stresses. In earlier publications, different shear cutting techniques, the near-net-shape-blanking processes (NNSBP’s), were investigated regarding a favorable residual stress state. The influence of the process parameters on the amount of clean cut, surface roughness, hardness and residual stresses was investigated. Furthermore, fatigue bending tests were carried out using C-shaped specimens. This paper reports about involute gears that are manufactured by fineblanking. This NNSBP was identified as suitable based on the previous research, because it led to a high amount of clean cut and favorable residual stresses. For the fineblanked gears of S355MC (1.0976), the die edge radii were varied and the effects on the cut surface geometry, hardness distribution, surface roughness and residual stresses are investigated. The accuracy of blanking the gear geometry is measured, and the tooth root bending strength is determined in a pulsating test rig according to standardized testing methods. It is shown that it is possible to manufacture gears by fineblanking with a high precision comparable to gear hobbing. Additionally, the cut surface properties lead to an increased tooth root bending strength.

The Compliance Method for Measurement of Near Surface Residual Stresses—Analytical Background

1994 ◽  
Vol 116 (4) ◽  
pp. 550-555 ◽  
Author(s):  
M. Gremaud ◽  
W. Cheng ◽  
I. Finnie ◽  
M. B. Prime
Keyword(s):  
Numerical Simulation ◽  
Residual Stresses ◽  
Random Errors ◽  
Residual Stress Field ◽  
Near Surface ◽  
Surface Residual Stresses ◽  
Zero Shift ◽  
Stress States ◽  
The Stability ◽  
Piecewise Functions

Introducing a thin cut from the surface of a part containing residual stresses produces a change in strain on the surface. When the strains are measured as a function of the depth of the cut, residual stresses near the surface can be estimated using the compliance method. In previous work, the unknown residual stress field was represented by a series of continuous polynomials. The present paper shows that for stress states with steep gradients, superior predictions are obtained by using “overlapping piecewise functions” to represent the stresses. The stability of the method under the influence of random errors and a zero shift is demonstrated by numerical simulation.

Residual Stress in Bone: A Parametric Study

2008 ◽  
Author(s):  
A. Hizal ◽  
B. Sadasivam ◽  
D. Arola
Keyword(s):  
Residual Stress ◽  
Particle Size ◽  
Residual Stresses ◽  
Material Removal ◽  
Surface Deformation ◽  
Radius Of Curvature ◽  
Near Surface ◽  
Size And Shape ◽  
Air Jet ◽  
Particle Size And Shape

A preliminary study was conducted to evaluate the parametric dependence of the residual stress distributions in bone that result from an abrasive air-jet surface treatment. Specifically, the influence of particle size and shape used in the treatment on the residual stress, propensity of embedding particles and material removal were studied. Rectangular beams of cortical bone were prepared from bovine femurs and treated with aluminum oxide and glass particles with different treatment angles. Residual stresses within the bone were quantified in terms of the radius of curvature of the bone specimens measured before and after the treatments, as well as a function of time to quantify decay in the stress. The sub-surface distribution was also examined using the layer removal technique. Results showed that the particle size and shape could be used to control the amount of material removal and the magnitude of residual stress within the treated surfaces. An increase in size of the glass particles resulted in an increase in the residual stress and a decrease in material removed during the treatment. The magnitude of residual stress ranged from 22 MPa to nearly 44 MPa through modulation of the particle qualities (size and shape). A microscopic examination of the treated surfaces suggests that the residual stresses resulted primarily from near-surface deformation.

Crystal Plasticity Modeling of Laser Peening Effects on Tensile and High Cycle Fatigue Properties of 2024-T351 Aluminum Alloy

2021 ◽  
Vol 143 (7) ◽  
Author(s):  
Maziar Toursangsaraki ◽  
Huamiao Wang ◽  
Yongxiang Hu ◽  
Dhandapanik Karthik
Keyword(s):  
Residual Stresses ◽  
Crystal Plasticity ◽  
High Cycle Fatigue ◽  
Driving Forces ◽  
Crack Nucleation ◽  
Fatigue Properties ◽  
Laser Peening ◽  
Cycle Fatigue ◽  
Fatigue Crack Nucleation ◽  
Near Surface

Abstract This study aims to model the effects of multiple laser peening (LP) on the mechanical properties of AA2024-T351 by including the material microstructure and residual stresses using the crystal plasticity finite element method (CPFEM). In this approach, the LP-induced compressive residual stress distribution is modeled through the insertion of the Eigenstrains as a function of depth, which is calibrated by the X-ray measured residual stresses. The simulated enhancement in the tensile properties after LP, caused by the formation of a near-surface work-hardened layer, fits the experimentally obtained tensile curves. The model calculated fatigue indicator parameters (FIPs) under the following cyclic loading application show a decrease in the near-surface driving forces for the crystal slip deformation after the insertion of the Eigenstrains. This leads to a higher high cycle fatigue (HCF) resistance and the possible transformation of sensitive locations for fatigue failure further to the depth after LP. Experimental observations on the enhancement in the HCF life, along with the relocation of fatigue crack nucleation sites further to the depth, reveal the improvement in the HCF properties due to the LP process and validate the numerical approach.

Fracture of Ceramics with Near Surface Gradient Residual Stresses

2007 ◽  
Vol 333 ◽  
pp. 97-106
Author(s):  
Marc Anglada
Keyword(s):  
Fracture Toughness ◽  
Residual Stresses ◽  
Graded Materials ◽  
Near Surface ◽  
Apparent Fracture Toughness ◽  
Surface Gradient ◽  
Compressive Stresses ◽  
Small Cracks ◽  
Monolithic Ceramics ◽  
Compressive Residual Stresses

The fracture toughness and strength of ceramics can be improved with respect to monolithic ceramics by developing graded materials as laminates composed of periodic alternating layers of one material separated by layers of a second material. The second layer must contain residual compressive stresses which are induced during densification because of differential thermal contraction of the layers. The overall residual stresses increase the apparent fracture toughness of the laminate. However, most deleterious natural flaws and most of the damage induced in service by the environment, contact loading, wear, etc, are small cracks on the surface of the outer layer, so that the effect of the laminate residual stresses on these cracks should be rationalised to understand their behaviour. This work presents an analysis of the influence of the gradient residual stresses on the behaviour of surface cracks under bending and indentation in materials with outer layers either with tensile or compressive residual stresses.

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