Prediction of residual stress fields from surface stress measurements

Wang, Fengyun; Mao, Kuanmin; Li, Bin

doi:10.1016/j.ijmecsci.2018.02.043

Cited by 33 publications

(7 citation statements)

References 33 publications

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“…The identification of residual stresses is an inverse problem of solid body mechanics. This problem belongs to the class of ill-posed problems [37][38][39][40]. The knowledge of manufacturing history and the computational approach described above may be useful for computation of residual stresses on the ground of experimental measurements.…”

Section: Discussionmentioning

confidence: 99%

Numerical modeling of residual stresses in additive manufacturing products using the theory of repeatedly superimposed finite strains

Левин

Зингерман

Вершинин

et al. 2022

Mathematics and Mechanics of Solids

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An approach to the residual stress analysis of parts made by powder bed additive manufacturing is proposed. The approach is based on the theory of repeatedly superimposed finite strains. The problem statement is formulated within the framework of nonlinear thermoelasticity. The method of problem solving is developed on the base of finite and spectral element methods. The numerical modeling of a full-sized experiment is performed. In this experiment, the additive manufactured part is notched in order to estimate residual stresses in it. The obtained numerical results are in good agreement with the experimental results. It is concluded from the results that the developed approach is correct and the nonlinear effects are substantial.

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Section: Discussionmentioning

confidence: 99%

Numerical modeling of residual stresses in additive manufacturing products using the theory of repeatedly superimposed finite strains

Левин

Зингерман

Вершинин

et al. 2022

Mathematics and Mechanics of Solids

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“…As illustrated above, in Step 3, we input the conductivity distribution in the numerical model according to Equation (8) and can get the detection signals under different applied loads. Then, in Step 4 we can obtain the relationship of FS and calculate the coefficient of determination R s between the F~S and experimental data from the eddy current technique.…”

Section: Hybrid Approach For Inhomogeneous Distribution Stressmentioning

confidence: 99%

“…Stress concentration, or residual stress, is the main cause of the micro cracks in metal components and structures (such as oil/gas pipeline [1,2], airfoil [3], steel bridge [4], hoisting equipment [5], and polycrystalline solids [6]). Consequently, the microcracks in such key components and subassemblies can suddenly cause structure failure when operating under alternating loads; this may lead to economic and environmental losses, as well as human casualties [7,8], if there is no appropriate maintenance strategy. Therefore, the evaluation approach to the stress distribution is essential to control the early stage quality and to extend the lifetime by structural health monitoring.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Inhomogeneous Stress in Metal Structures: A Hybrid Approach Combining Eddy Current Technique and Finite Element Method

Yuan

et al. 2021

Journal of Sensors

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Concentrated stresses and residual ones are critical for the metal structures’ health, because they can cause microcracks that require emergency maintenance or can result in potential accidents. Therefore, an accurate approach to the measurement of stresses is key for ensuring the health of metal structures. The eddy current technique is an effective approach to detect the stress according to the piezoresistive effect. However, it is limited to detect the surface stress due to the skin effect. In engineering, the stress distribution is inhomogeneous; therefore, to predict the inhomogeneous stress distribution, this paper proposes a nondestructive approach which combines the eddy current technique and finite element (FE) method. The experimental data achieved through the eddy current technique determines the relationship between the applied force and the magnetic flux density, while numerical simulations through the FE method bridge the relationship between the magnetic flux density and the stress distribution in different directions. Therefore, we can predict the inhomogeneous stress nondestructively. As a case study, the applied stress in a three-point-bending simply supported beam was evaluated, and the relative error is less than 8% in the whole beam. This approach can be expected to predict the residual stress in metal structures, such as rail and vehicle structures, if the stress distribution pattern is known.

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“…Acoustic characteristic obtained via an ultrasonic stress measurement can be incorporated with FE model to capture through thickness residual stress in three-dimensional body [17]. Full field residual stress can also be estimated without process simulation via a finite element algorithm using only the measurement of surface residual stress [18]. Recently, an analytical residual stress estimation process based on elastoplastic analysis with an arbitrary heat source model is proposed where use of finite element model can be completely excluded [19].…”

Section: Introductionmentioning

confidence: 99%

A mixed-finite element approach for full-field residual stress estimation

Naskar

Banerjee

2022

ASPS Conf. Proc.

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In this paper, a full-field residual stress identification technique has been presented via a mixed finite element approach from limited measured detail. Being an inverse problem, complete identification of residual stresses from incomplete measurement is always suffered by inherent ill-posedness. To control this issue, the identification problem has been formulated as an optimization problem via a Tikhonov type cost functional. The first part of this cost functional is associated with an energy norm of mismatch between predicted and measured residual stress. The second part represents the regularization term. A Lagrangian is then considered to satisfy the equilibrium constraint over the region of interest. The incorporation of Lagrangian with aforementioned cost functional provides a form which is very similar to the standard Hellinger-Reissner (HR) functional except the discrepancy term between the data. The minimization of this formulation leads to the solution of two-field mixed variational form associated with residual stress and Lagrangian variable. To show the efficacy of the proposed procedure a two-dimensional welded specimen is considered where the weld bead is assumed to be spatially varying in all direction for residual stress identification. Line scan details are also presented to examine the deviation between the actual and predicted residual stress in the heat affected zone and at the region away from the weld bead. The results indicate that the mixed finite element formulation has the capability to provide the complete information of residual stress despite of having very few information of measurement.

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Prediction of residual stress fields from surface stress measurements

Cited by 33 publications

References 33 publications

Numerical modeling of residual stresses in additive manufacturing products using the theory of repeatedly superimposed finite strains

Numerical modeling of residual stresses in additive manufacturing products using the theory of repeatedly superimposed finite strains

Prediction of Inhomogeneous Stress in Metal Structures: A Hybrid Approach Combining Eddy Current Technique and Finite Element Method

A mixed-finite element approach for full-field residual stress estimation

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