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Abstract: This study investigates and compares the effects of different shot peening treatments including conventional and severe shot peening on microstructure, mechanical properties, fatigue behavior, and residual stress relaxation of AISI 1060 steel. Shot peening treatments were applied with two Almen intensities of 17 and 21 A and a wide ranges of coverage (100%–1500%). Various microstructural observations were carried out to analyze the evolution of microstructure. Microhardness, residual stress and surface roughness measurements and also axial fatigue test were performed. Moreover, the extent of the residual stress relaxation during cyclic loading was investigated by means of XRD... 

Shot peening is one of the most effective surface strengthening treatment technologies in which compressive residual stresses are induced beneath the specimen surface. Effects of various factors on the distribution of residual stress profile induced by shot peening have been investigated by many researchers. However, initial residual stresses are one of the important factors which affect the shot peening residual stress.This study is aimed to present comprehensive numerical and experimental study on the effect of initial residual stresses on the shot peened specimen. Initial residual stresses were induced using a four-point bending rig and grinding. Incremental center hole drilling (ICHD)... 

The qualitative effects of residual stress parameters on fatigue crack growth are investigated using Monte Carlo probabilistic analysis technique. These parameters include the maximum residual stress,σ0, half-width of the tensile residual stress region, b, and the redistribution of residual stress parameter, β. A normal distribution is assumed for all parameters considered in the investigation and fatigue life is determined using Forman equation. The results indicate that: (i) fatigue life decreases nonlinearly if the mean of random maximum residual stress and the half-width of tensile residual stress region increases; (ii) fatigue life increases nonlinearly if the rate of residual stress... 

Residual stresses are inherent in parts manufactured using the wire + arc additive manufacturing (WAAM) technique, resulting in unpredictable mechanical response and structural integrity (Colegrove et al.: J Mater Process Technol 213:1782-1791, 2013). An effective post-processing technique, which enhances the mechanical properties of WAAM parts, is rolling. This study investigates the vertical and pinch rolling effects on residual stress distribution in WAAM components. Initially, a WAAM model was created using a thermo-mechanical finite element modelling approach and validated against the experimental results. Subsequent to the validation of the model, the effect of the main parameters... 

Radial forging and indentation forging processes are two processes used for sizing and/or internal profiling of tubes. In this paper, the two processes are simulated using finite element method and their results are compared with Experimental results. The purpose of this paper is to compare the pattern of residual stresses in both processes. Copyright © 2005 SAE International  

The calculation of loading and residual stresses, and associated strains and displacements, are reported for shrink fitted rotating discs at elevated temperatures. A range of material behaviour is considered including unloading described by an actual material curve, or modelled by isotropic of kinematic hardening with a variable Bauschinger effect. Various collapse loads are obtained and discussed for design boundaries. The influence of reloading on the residual stresses is also studied. It is shown that after the first few loadings of a disc, the residual stress field becomes constant. © 2001 Elsevier Science Ltd. All rights reserved  

In this paper residual stresses induced by butt metal arc gas welding (MAGW), in accordance with ASTM E837, are determined by hole drilling. The results are analyzed by probabilistic methods. Also, the effect of fatigue life on relaxation of welding residual stress is investigated. The specimens are tested to measure fatigue life and crack growth rates in accordance with ASTM E466 for force controlled amplitude axial fatigue testing. © 2008 Verlag Stahleisen GmbH, Düsseldorf  

This study concentrates on the effects of weld sequence and welding fixtures on distribution and magnitude of induced arc welding residual stresses built up in butt-joint of Gas Tungsten Arc Welding (GTAW) AA5251 plates. Aluminum plates have been welded under different welding conditions and then, longitudinal and transverse residual stresses were measured in different points of the welded plates employing hole-drilling technique. The results indicate that welding sequence significantly alters the distributions of both longitudinal and transverse residual stresses while the changing in the weld sequence leads to 44% decrease in longitudinal residual stress. Besides, both the geometry of weld... 

In order to improve the fatigue performance of torsion bar, induction surface hardening is performed. The aim of the present study is to compare the experimental residual stress fields measured by X-ray diffraction with those predicted from finite element modeling of the whole induction surface hardening process. Temperature and residual stress distributions are affected by the component geometry, the material behavior and the induction treatment parameters. Based on the residual stress distribution and the fatigue loading, cracks can nucleate from the surface or below the hardened layer. Therefore, it is very important to determine the residual stress distribution and optimize the process,... 

Grinding is widely used for manufacturing of components that require fine surface finish and good dimensional accuracy. In this study a thermo-mechanical finite element analysis is conducted to find out how grinding parameters can affect temperature and residual stress distribution in the workpiece. Results of parametric study presented in this work indicate, by carefully selecting the grinding parameters, minimum thermal and mechanical damage can be achieved. Higher workpiece velocities produce higher surface residual stress. By increasing depths of cut, depth of tensile residual stresses increases. Convection heat coefficient does not have any considerable effect on surface residual stress... 

Laser shock peening (LSP) is one of the life enhancement processes by inducing compressive residual stresses into the material. The effects of repeating LSP pattern on the residual stress is investigated numerically in this study. A 3-D finite element model was developed to obtain residual stress field in the material. FEM results have shown that increasing the number of peening impacts increase the magnitude and depth of compressive residual stress. Also the average surface residual stress in the impact region increased from −291 after 1 impact to −326, −343 and −356 MPa after 2, 3 and 4 impacts respectively. Moreover, the effects of repeating LSP pattern on fatigue crack growth properties... 

In this paper an analysis is presented to determine the distribution of a residual stress field from a limited incomplete set of measurements obtained from shot-peened round steel bars. Using an Airy stress function as the primary unknown the axisymmetric stress equations are solved directly. In this new method there exists the flexibility to impose physical conditions that govern the behavior of residual stress to achieve a meaningful complete stress field. This new method aims to achieve the best agreement between the model prediction and limited measured stress components in the sense of least squares approximation. The power of this new method is demonstrated by analyzing experimental... 

Shot peening (SP) and also severe shot peening (SSP) provide high level compressive residual stress on a certain thickness just beneath the surface. By exposing severe plastic deformation (SPD) via SSP, the nanocrystallization is formed without any chemical alteration and the structure is to be hardened by fully mechanized process. The difference among SP, SSP and repeening (RP) is only related with the selection of the input parameters. Most of the input parameters combination constructs the Almen intensity which is the most powerful condition to be made the decision on the final shot peening of real parts. AISI 1045 medium carbon steel is selected for the optimization of input parameters... 

An analytical solution is presented that reconstructs residual stress field from limited and incomplete data. The inverse problem of reconstructing residual stresses is solved using an appropriate form of the airy stress function. This function is chosen to satisfy the stress equilibrium equations together with the boundary conditions for a domain within a convex polygon. The analytical solution is demonstrated by developing a reference solution from which selected "measurement" points are used. An artificial error is then randomly added to "measurement" points for studying the stability of the reconstruction method utilizing Tikhonov- Morozov regularization technique. It is found that there... 

Titanium matrix composites (TMCs) have wide application prospects in the field of aerospace, automobile and other industries because of their good properties, such as high specific strength, good ductility, and excellent fatigue properties. However, in order to improve their fatigue strength and life, crack initiation and growth at the surface layers must be suppressed using surface treatments. Shot peening (SP) is an effective surface mechanical treatment method widely used in industry which can improve the mechanical properties of a surface. However, artificial neural networks (ANNs) have been used as an efficient approach to predict and optimize the science and engineering problems. In... 

The effect of welding current and polarity, i.e. AC and DCEN, on imposed thermal cycles, mechanical properties, microstructural events and residual stresses was investigated in GTA welding of AA5052. A three-dimensional thermo-mechanical model was utilized to evaluate thermal responses and residual stresses distribution in the weldments. Tensile testing and hardness measurements were also conducted to study the effect of welding polarity on the mechanical properties of components. Microstructural observations utilizing optical microscopy were carried out to assess the microstructural evolutions. The results show that wide varieties of microstructures are produced in DCEN sample from cells at... 

In the present study, an electro-thermo-mechanical model is utilized to predict electrical potential, temperature and residual stress distributions during different stages of resistance spot welding. In order to improve accuracy, material properties including physical, thermal and mechanical properties supposed to be temperature-dependent. The employed model is capable of considering the effects of welding parameters such as heat input and welding time on residual stress distribution. The model results are then compared with the measured residual stresses and good agreement is observed. Predictions show that maximum tensile residual stresses are located at the weld center while they are... 

In this paper, using numerical solutions of bore and outer radius hoop residual stresses in various tube geometries for autofrettage prior to shrink fit and shrink fit prior to autofrettage design are investigated, and the results are compared with monobloc autofrettaged and shrunk fit tubes. Both of the former compound tubes induce more compressive bore hoop residual stresses than a monobloc autofrettage and shrunk fit case. Furthermore, in geometries in which maximum bore hoop residual stresses are induced, the outer radius experiences acceptably low tensile residual stresses. Bore hoop residual stresses increase with increase of tube outer radius; however the rate of increasing decreases.... 

In this work, a comprehensive study of radial forging process is presented through 2-D axisymmetric and 3-D finite element simulations while considering internal tube profile. The tube used in this investigation has four internal helical grooves along its length. The material is modeled with the elastic-plastic behavior, and sliding-sticking friction model is utilized to model the die-workpiece and mandrel-workpiece contacts. The numerical results in the 2-D case are compared with available experimental data. Residual stresses in the forged product, stress concentration around the grooves, pressure distribution on the hammers and mandrel and maximum forging load are studied. The effects of... 

316L stainless steel is widely used as cathode blank in copper electrorefining. These cathode blanks become distorted through the cathode stripping in the cathode stripping machine and must be straightened before using again. After several times repeated cold straightening, the cathode blank spring backs to its distorted position during electrorefining resulted in short circuits and current efficiency decreases. The objectives of this study were to: i) investigate the cathode blank spring back behavior and properties; ii) propose a solution adhere to the subject. To achieve these goals, more than 20 samples are selected and cut into small pieces to simulate the cold straightening process....