Experimental and numerical study of residual stresses caused by cold expansion of adjacent holes

Seifi, Rahman; Zolfaghari, Mehrdad; Shirazi, Ali

doi:10.1007/s11012-013-9820-x

Cited by 5 publications

(3 citation statements)

References 16 publications

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“…Zhang et al established a three-dimensional finite element model to simulate the SSCE process considering non-uniform stress distribution of the split sleeve, and found that the compressive stress value is the largest in the middle layer, the smallest in the squeeze layer, and the value in the extrude layer is between the two [ 24 ]. Based on numerical simulation and experimental testing methods, Seifi et al studied the effect of CE-induced residual stress of two adjacent holes on fatigue life and crack initiation period and analyzed the effect of expansion ratio and distance between adjacent holes on total life and crack growth life [ 25 , 26 ]. Kumar et al conducted a 3D finite element simulation of continuous CE of two adjacent holes in an Al 7075-T651 plate.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis of Split Sleeve Cold Expansion Process on Multiple Hole Aluminum Alloy

et al. 2023

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Multiple cold expansion holes are widely used in connection areas of aircraft structures, in order to achieve uniform load transfer of the skin or connection parts. Split sleeve cold expansion (SSCE) is widely used to enhance the fatigue life of fastener holes by applying compressive residual stresses around the holes. In this study, the finite element method (FEM) was used to research the distribution and variation of residual stresses along the hole edges of 7075AA single-hole and multi-hole cold expansion (CE) specimens. Full-field strain measurements of single-hole and multi-hole specimens were performed using two-dimensional digital image correlation (DIC), and the residual stress and strain at the hole edge of the specimens measured by FEM and DIC were compared. FEM results shows that the maximum circumferential and radial residual stresses of three-hole specimens with three-hole spacing are increased by 5.37% and 31.53% compared with single-hole specimens. The maximum circumferential residual stress of three-hole specimens with four-hole spacing increases by 7.25% compared with a single hole, but the radial residual stress decreases by 12.98%. In addition, for three-hole specimens with hole spacing three times the hole diameter, the strengthening effect of SSCE in the order of middle hole, then left hole, and, finally, right hole is better than that of SSCE in the order of left to right hole. FEM and DIC full-field strain results are basically consistent.

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Section: Introductionmentioning

confidence: 99%

Finite Element Analysis of Split Sleeve Cold Expansion Process on Multiple Hole Aluminum Alloy

et al. 2023

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“…Sun [19] used a hydraulic expansion method to obtain the cooling air tube of aero gas turbine engine, and the wrinkling and fracture defects were effectively controlled with an 80 MPa pressure and a 5-mm feed rate. Seifi et al [20] pointed out that the cold expansion process changed the distribution of residual stress around the holes of plate. Lăzărescu et al [21] proposed a new methodology that combined an analytical approach with the experiment data measured by a 3D optical measurement system, and this methodology was used to determine the equivalent stress-strain curves by bulging through elliptical dies.…”

Section: Introductionmentioning

confidence: 99%

Residual Stress Analysis of a 2219 Aluminum Alloy Ring Using the Indentation Strain-Gauge Method

Ma¹,

Xue

et al. 2020

Metals

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Aerospace thin-walled rings are vulnerable to machining distortion during the manufacturing process. Various research results show that the main factor causing machining deformation is initial residual stress inside the blank. In this study, the residual stress of a 2219 aluminum alloy ultra-large rolling ring was measured by using the indentation strain-gauge method. Results showed the maximum residual maximum principal stress was +265 MPa and stress distribution was uneven. To homogenize the initial residual stress of the ring, an expansion method is proposed based on the principle of pre-stretching plate, and the feasibility of the expansion method was analyzed by establishing a simplified theoretical model of ring. A FE (Finite Element) model was established to investigate residual-stress evolution during the rolling ring and the expanding ring process. The expansion simulation results show that the reduction rates of residual stress were greater than 40% and the maximum residual stress was only 65 MPa.

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“…Residual stress field is evaluated using a nonlinear analysis and superposed with the applied stresses field in order to estimate fatigue crack growth. Seifi et al [12] show experimental and numerical results for two different aluminum alloys and various holes distances. The maximum expansion level used is about 4%.…”

Section: Introductionmentioning

confidence: 99%

Effect of the indentation process on fatigue life of drilled specimens

et al. 2015

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Design and manufacture of mechanical elements are strongly influenced by the evaluation of the residual stresses due to their effects on the material strength. This paper presents numerical and experimental results performed on AW 6082-T6 aluminum alloy drilled specimens when the hole is created after a bilateral indentation process. The plastic deformation induced by the indenters creates a compressive residual stress field around the hole, which persists after the drilling operation. Several numerical analysis have been carried out in ANSYS APDL explicit solver for different indentation depths and hole diameters in order to evaluate the compressive circumferential stresses, optimal process parameters and relevant geometric features. Fatigue tests are performed in order to determine the cycles to failure and the corresponding Wöhler diagram

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Experimental and numerical study of residual stresses caused by cold expansion of adjacent holes

Cited by 5 publications

References 16 publications

Finite Element Analysis of Split Sleeve Cold Expansion Process on Multiple Hole Aluminum Alloy

Finite Element Analysis of Split Sleeve Cold Expansion Process on Multiple Hole Aluminum Alloy

Residual Stress Analysis of a 2219 Aluminum Alloy Ring Using the Indentation Strain-Gauge Method

Effect of the indentation process on fatigue life of drilled specimens

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