Residual Stresses Measurement in Hollow Samples Using Contour Method

Document Type : Original Article

Authors

1 Mechanical Engineering Department, Bu-Ali Sina University, Hamedan, Iran

2 Department of Engineering and Innovation, The Open University, Milton Keynes, UK

Abstract

Residual stresses are created usually undesirably during manufacturing processes, including casting, welding, metal forming, etc. Residual stresses alone or in combination with other factors can cause the destruction and fracture of components or significant decline in their service life. Therefore, it is crucial to measure the residual stresses. Contour method is a destructive testing method capable of measuring residual stresses of the cut surface along with being simple and low-cost. This method is able to create a two-dimensional map of residual stresses perpendicular to the sectioned surface. Measuring hollow samples is still a dilemma when using the contour method. In this study, hollow cylindrical samples with inner diameters of 20 and 40 mm were quenched at temperatures of 300ºC, 400ºC, and 850ºC. Both numerical analyses and experimental measurements were performed for the samples. The contour method was practiced for both hollow and filled samples. Overall review of the results was promising. However, the results obtained in the vicinity of the edges illustrated large deviations. Steel shafts were inserted to cylindrical holes to rectify the lack of constraint near the edges. The measurements on the filled samples were greatly improved. 

Keywords

References

7. REFERENCES
 
1. Totten, G.E., "Handbook of residual stress and deformation of
steel, ASM international,  (2002). 
2. Prime, M.B., "Residual stress measurement by successive
extension of a slot: The crack compliance method",  Applied
Mechanics Reviews, Vol. 52 (1999) 75-96  
3. Withers, P., "Residual stress and its role in failure", Reports on
Progress in Physics,  Vol. 70, No. 12, (2007), 2211-2264. 
4. Withers, P.J. and Bhadeshia, H., "Residual stress. Part 1–
measurement techniques", Materials Science and Technology, 
Vol. 17, No. 4, (2001), 355-365. 
5. Johnson, G., "Residual stress measurements using the contour
method, The University of Manchester (United Kingdom), 
(2008). 
6. Prime, M.B., "Cross-sectional mapping of residual stresses by
measuring the surface contour after a cut", Journal of
Engineering Materials and Technology,  Vol. 123, No. 2,
(2001), 162-168. 
7. Bueckner, H., "The propagation of cracks and the energy of
elastic deformation", Transaction of the ASME, Series E,  Vol.
80, No. 6, (1958), 1225-1230. 
8. Zhang, Y., Pratihar, S., Fitzpatrick, M.E. and Edwards, L.,
"Residual stress mapping in welds using the contour method", in
Materials science forum, Trans Tech Publ. Vol. 490, (2005), 294299.
9. Prime, M., Weld application of a new method for cross-sectional
residual stress mapping. 2001, Los Alamos National Lab., NM
(US). 
10. Zhang, Y., Ganguly, S., Edwards, L. and Fitzpatrick, M., "Crosssectional
mapping
of
residual
stresses
in a vppa weld using the
contour method", Acta Materialia,  Vol. 52, No. 17, (2004), 52255232.
11. Prime, M.B. and Martineau, R.L., "Mapping residual stresses
after foreign object damage using the contour method", in
Materials science forum, Trans Tech Publ. Vol. 404, (2002), 521526.
12. Prime, M.B., Residual stresses measured in quenched hsla-100
steel plate. 2005, Los Alamos National Laboratory. 
13. Prime, M.B., Gnäupel-Herold, T., Baumann, J.A., Lederich, R.J.,
Bowden, D.M. and Sebring, R.J., "Residual stress measurements
in a thick, dissimilar aluminum alloy friction stir weld", Acta
Materialia,  Vol. 54, No. 15, (2006), 4013-4021. 
14. Richter-Trummer, V., Tavares, S.M., Moreira, P.M., de
Figueiredo, M.A. and de Castro, P.M., "Residual stress
measurement using the contour and the sectioning methods in a
mig weld: Effects on the stress intensity factor", Ciência & 
Tecnologia dos Materiais,  Vol. 20, No. 1-2, (2008), 114-119. 
15. Murugan, N. and Narayanan, R., "Finite element simulation of
residual stresses and their measurement by contour method",
Materials & Design,  Vol. 30, No. 6, (2009), 2067-2071. 
16. Mahmoudi, A., Hosseinzadeh, A.R. and Jooya, M., "Plasticity
effect on residual stresses measurement using contour method", 
International Journal of Engineering, Transactions A: Basics,
Vol. 26(10) (2013) 1203-1212. 
17. Hosseinzadeh, F., Kowal, J. and Bouchard, P.J., "Towards good
practice guidelines for the contour method of residual stress
measurement", The Journal of Engineering,  Vol. 2014, No. 8,
(2014), 453-468. 
18. Liu, C. and Yi, X., "Residual stress measurement on aa6061-t6
aluminum alloy friction stir butt welds using contour method",
Materials & Design,  Vol. 46, (2013), 366-371. 
19. Toparli, M. and Fitzpatrick, M.E., "Development and application
of the contour method to determine the residual stresses in thin
laser-peened aluminium alloy plates", Experimental Mechanics, 
Vol. 56, No. 2, (2016), 323-330. 
20. Toparli, M., Fitzpatrick, M.E. and Gungor, S., "Improvement of
the contour method for measurement of near-surface residual
stresses from laser peening", Experimental Mechanics,  Vol. 53,
No. 9, (2013), 1705-1718. 
21. DeWald, A. and Hill, M., "Multi-axial contour method for
mapping residual stresses in continuously processed bodies",
Experimental Mechanics,  Vol. 46, No. 4, (2006), 473. 
22. Turski, M. and Edwards, L., "Residual stress measurement of a
316l stainless steel bead-on-plate specimen utilising the contour
method", International Journal of Pressure Vessels and Piping, 
Vol. 86, No. 1, (2009), 126-131. 
23. Prime, M.B., Contour method advanced applications: Hoop
stresses in cylinders and discontinuities, in Engineering
applications of residual stress, volume 8. 2011, Springer.13-28. 
24. Hosseinzadeh, F., Traore, Y., Bouchard, P. and Muránsky, O.,
"Mitigating cutting-induced plasticity in the contour method, part
1: Experimental", International Journal of Solids and
Structures,  Vol. 94, (2016), 247-253. 
25. Muransky, O., Hamelin, C.J., Hosseinzadeh, F. and Prime, M.B.,
"Mitigating cutting-induced plasticity in the contour method. Part
2: Numerical analysis", International Journal of Solids and
Structures,  Vol. 94, (2016), 254-262. 
26. Mahmoudi, A. and Saei, A., "Influence of asymmetrical cuts in
measuring residual stresses using contour method", International
Journal of Pressure Vessels and Piping,  Vol. 134, (2015), 1-10. 
27. Prime, M.B. and Kastengren, A.L., The contour method cutting
assumption: Error minimization and correction, in Experimental
and applied mechanics, volume 6. 2011, Springer.233-250. 
28. Ahmad, B. and Fitzpatrick, M.E., "Minimization and mitigation
of wire edm cutting errors in the application of the contour
method of residual stress measurement", Metallurgical and
Materials Transactions A,  Vol. 47, No. 1, (2016), 301-313. 
29. Werke, M., Hossain, M., Semere, D. and Wretland, A.,
"Machining distortion analysis of aerospace components using
the contour method", in FT2019. Proceedings of the 10th
Aerospace Technology Congress, October 8-9, 2019, Stockholm,
Sweden, Linköping University Electronic Press. (2019), 216-222. 
30. Ahmad, B., van der Veen, S.O., Fitzpatrick, M.E. and Guo, H.,
"Residual stress evaluation in selective-laser-melting additively
manufactured titanium (ti-6al-4v) and inconel 718 using the
contour method and numerical simulation", Additive
Manufacturing,  Vol. 22, (2018), 571-582. 
31. Liu, C., Wang, C., Cheng, X., Yan, Y., Yang, J. and Guo, Y.,
"Experimental investigation on the residual stresses in a thick
joint with a partial repair weld using multiple-cut contour
method", Materials,  Vol. 11, No. 4, (2018), 633. 
32. Schajer, G.S., "Practical residual stress measurement methods,
John Wiley & Sons,  (2013). 
33. Traore, Y., Bouchard, P.J., Francis, J. and Hosseinzadeh, F., "A
novel cutting strategy for reducing plasticity induced errors in
residual stress measurements made with the contour method", in
ASME 2011 pressure vessels and piping conference, American
Society of Mechanical Engineers Digital Collection. (2011),
1201-1212. 
34. Kunieda, M., Lauwers, B., Rajurkar, K.P. and Schumacher, B.,
"Advancing edm through fundamental insight into the process",
CIRP Annals,  Vol. 54, No. 2, (2005), 64-87. 
35. Bouchard, P.J., Ledgard, P., Hiller, S. and Hosseinzadh
Torknezhad, F., "Making the cut for the contour method",  (2012).
http://oro.open.ac.uk/id/eprint/34114 
International Journal of Engineering
Volume 33, Issue 5
TRANSACTIONS B: Applications
May 2020
Pages 885-893

Files

Share

How to cite

Statistics