Simulation of Removing Autofrettage-induced Residual Stress Loaded Layers by Finite Element Analysis

Bähre, Dirk; Brünnet, Horst

doi:10.1016/j.proeng.2011.11.072

Cited by 8 publications

(8 citation statements)

References 9 publications

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“…But compared to the residual stresses after AF the amount is significantly reduced. This is consistent to the findings in [5]. The material removal causes a loss in compressive residual stresses and can hence affect the fatigue life of the components.…”

Section: Residual Hoop Stress [Mpa]supporting

confidence: 92%

“…Forming, heat treatment or machining processes introduce residual stresses themselves [2,3,4]. If applied after AF, finishing processes like reaming or honing remove layers with residual stress, thereby changing the final residual stress distribution [5,6]. In order to analyze the change in the residual stress distribution, the residual stresses have to be measured over a certain component depth.…”

Section: Introductionmentioning

confidence: 99%

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Modeling and Measurement of Residual Stresses along the Process Chain of Autofrettaged Components by Using FEA and Hole-Drilling Method with ESPI

Brünnet

Bähre

Rickert³

et al. 2013

MSF

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The incremental hole-drilling method is a well-known mechanical measurement procedure for the analysis of residual stresses. The newly developed PRISM® technology by Stresstech Group measures stress relaxation optically using electronic speckle pattern interferometry (ESPI). In case of autofrettaged components, the large amount of compressive residual stresses and the radius of the pressurized bores can be challenging for the measurement system. This research discusses the applicability of the measurement principle for autofrettaged cylinders made of steel AISI 4140. The residual stresses are measured after AF and after subsequent boring and reaming. The experimental residual stress depth profiles are compared to numerically acquired results from a finite element analysis (FEA) with the software code ABAQUS. Sample preparation will be considered as the parts have to be sectioned in half in order to access the measurement position. Following this, the influence of the boring and reaming operation on the final residual stress distribution as well as the accuracy of the presented measurement setup will be discussed. Finally, the usability of the FEA method in early design stages is discussed in order to predict the final residual stress distribution after AF and a following post-machining operation.

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Section: Residual Hoop Stress [Mpa]supporting

confidence: 92%

Section: Introductionmentioning

confidence: 99%

Modeling and Measurement of Residual Stresses along the Process Chain of Autofrettaged Components by Using FEA and Hole-Drilling Method with ESPI

Brünnet

Bähre

Rickert³

et al. 2013

MSF

View full text Add to dashboard Cite

show abstract

“…This affects the load-bearing capacity of the component during service. Therefore, determining the residual stress loss caused by the machining process is crucial for accurately estimating the pressure-carrying capacity of the designed cylinder [9,10].…”

Section: Introductionmentioning

confidence: 99%

Parameter Sensitivity Analysis for Machining Operation of Autofrettaged Cylinder Using Taguchi Method

Oymak,

Yıldırım,

Yıldız

et al. 2024

Applied Sciences

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This study investigates the impact of material parameters such as yield strength (Sy), Young’s modulus (E), and tangent modulus (T) on the safety factor (SF) of autofrettaged cylinders under 400 MPa working pressure, considering the three scenarios: no machining, internal machining, and external machining. Finite element (FE) simulations were conducted based on the Taguchi experimental design and converted into signal-to-noise (S/N) ratios to determine the optimal settings. ANOVA was utilized to evaluate the significance and percentage contributions of each factor. The analysis indicated that Sy is the most influential parameter on SF, contributing approximately 98.20% across all scenarios, including no machining, internal machining, and external machining. The contributions of E and T were minimal, but T had a slightly greater effect than E. The analytical validation of the FE model showed good agreement, with a maximum deviation of 4.37% for no machining, 4.75% for internal machining, and 5.20% for external machining. Regression analysis further confirmed the high prediction capability of the model, validated using AISI 4340 steel. The study concludes that internal machining results in higher residual stress loss compared to external machining. Overall, the analytical method tends to provide lower SF values than the numerical method, highlighting its conservative nature.

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“…Parker [45], en 2001, propuso un procedimiento de diseño numérico para el autozunchado de cilindros de pared gruesa con extremos abiertos e incluso se comparó con el código ASME [18], siendo los resultados de Parker incorporados en él. También se han realizado númerosos estudios analizando la redistribución de tensiones tras la eliminación de material tras el autozunchado Estado del arte [43], [46]- [48]. Además se han realizado estudios en los que el autozunchado se junta con el zunchado térmico [43], [47], [49], [50] e incluso con otros métodos como el bobinado [22].…”

Section: Hidráulicounclassified

“…En las últimas décadas se han realizado números estudios utilizando simulación FEM para modelizar el autozunchado de los cilindros [46], [51]- [55].…”

Section: Hidráulicounclassified

Aplicación del proceso de swaging para la generación de tensiones residuales en componentes sometidos a altas presiones

Mingo¹

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Simulation of Removing Autofrettage-induced Residual Stress Loaded Layers by Finite Element Analysis

Cited by 8 publications

References 9 publications

Modeling and Measurement of Residual Stresses along the Process Chain of Autofrettaged Components by Using FEA and Hole-Drilling Method with ESPI

Modeling and Measurement of Residual Stresses along the Process Chain of Autofrettaged Components by Using FEA and Hole-Drilling Method with ESPI

Parameter Sensitivity Analysis for Machining Operation of Autofrettaged Cylinder Using Taguchi Method

Aplicación del proceso de swaging para la generación de tensiones residuales en componentes sometidos a altas presiones

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