Numerical and experimental study of the cold expansion process in 7085 plate using a modified split sleeve

Karabin, M.E.; Barlat, Frédéric; Schultz, Rebecca

doi:10.1016/j.jmatprotec.2007.01.008

Cited by 45 publications

(15 citation statements)

References 27 publications

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“…10,31 Mainly, it aims to remove the highly deformed material at the hole bore left by the process and prepare the hole for fastener application. 14 Also, the presence of highly deformed material at the hole bore has a detrimental effect on the fatigue life. The reaming step of removing 1 mm in radius is included in our numerical simulations 32 to estimate the stress distributions around the hole before applying a fastener.…”

Section: Workpiece and Ssce Tooling Configurationsmentioning

confidence: 99%

“…[4][5][6][7][8][9][10] The resulting circumferential compressive residual stresses are mainly responsible for improving the cold expanded holes' fatigue life because it retards crack initiation and propagation at the critical zones near hole edges. 4,8,[11][12][13][14] Fatigue Enhancement from the SSCE process is related to the magnitude and distribution of circumferential residual stress. Therefore, it is essential to quantify the residual stress magnitudes to achieve the best possible fatigue enhancement outcome from the SSCE process.…”

Section: Introductionmentioning

confidence: 99%

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Finite element parametric study of the split sleeve cold expansion on residual stresses and pulling force

Dey

Kim

Tan

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Split sleeve cold expansion (SSCE) is a crucial cost-effective process to improve the fatigue life of metallic structures with holes in the aerospace industry. In this study, the effects of the workpiece material’s yield strength (290.9 MPa to 377.8 MPa) and the applied SSCE expansion percentage (3.330% to 4.377%) on mandrel pulling force and residual stresses were investigated numerically for aluminum 2024-T351. A three-dimensional finite element (FE) model was developed to simulate the SSCE process using a commercial FE software, ABAQUS. The model geometries, material non-linearities, and contact conditions were adopted according to aerospace industrial applications’ standards. After the numerical model was validated with the published data, a parametric study with variable material properties and expansion percentage was conducted using the FE model. Our parametric study shows that an increase in both the Al workpiece’s yield strength and SSCE expansion percentage can improve the induced residual stresses in the hoop direction around the cold expanded hole; however, the workpiece’s yield strength has a higher impact on the residual stress field. The in-process pulling force during the SSCE process increases with increasing workpiece yield strength and expansion percentage.

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Section: Workpiece and Ssce Tooling Configurationsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Finite element parametric study of the split sleeve cold expansion on residual stresses and pulling force

Dey

Kim

Tan

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…Among the existing processes designed to generate extensive and controllable residual stress fields at the edge of the hole while minimizing damage to the hole surface, split sleeve cold expansion remains the most widely used in industry for aluminum applications . This process greatly improves the fatigue performance of the hole.…”

Section: Introductionmentioning

confidence: 99%

Optimization of the Cold Expansion Process for Titanium Holes

et al. 2016

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Cold expansion of metallic holes is widely used in the aerospace industry for improving the fatigue performance of mechanical assemblies. To increase the efficiency of the process, it is worth considering the possibility of carrying out the expansion twice in succession in the same hole. This paper discusses the consequences of such an operation on a single titanium hole through a numerical and experimental study. More precisely, numerical modeling is developed in order to simulate cases where the expansion is carried out twice: in the same direction and in opposite directions. The residual fields are analyzed and the results compared with experimental results using incremental hole-drilling technique. Results show that double expansion may have a very positive impact on the homogeneity of the compressive fields.

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“…de Matos et al [9] performed numerical simulations of cold working of rivet holes and compared the results obtained using models with different levels of complexity. Karabin et al [10] numerically investigated different sleeve designs on the stress concentration behavior of open holes. Though useful in some circumstances, the analytical model cannot provide accurate prediction of the residual stress field for cold expansion with split sleeves due to the involved complex conditions, including nonlinear contact, large deformation, and variation of sleeve design.…”

Section: Introductionmentioning

confidence: 99%

Effect of edge distance ratio on residual stresses induced by cold expansion and fatigue life of TC4 plates

Liu

Yang

et al. 2013

Engineering Fracture Mechanics

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Numerical and experimental study of the cold expansion process in 7085 plate using a modified split sleeve

Cited by 45 publications

References 27 publications

Finite element parametric study of the split sleeve cold expansion on residual stresses and pulling force

Finite element parametric study of the split sleeve cold expansion on residual stresses and pulling force

Optimization of the Cold Expansion Process for Titanium Holes

Effect of edge distance ratio on residual stresses induced by cold expansion and fatigue life of TC4 plates

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