MechanicalStressReliefSimulation-Ansys.pdfVIP

Mechanical Stress Relief Simulation David H. Johnson and Richard B. Englund Penn State – Erie, Erie, PA, USA Abstract A method of producing a known residual stress is sought so that methods for measurement of residual stress may be verified and calibrated. Equally, a clear classroom demonstration of a situation which causes residual stress and then relief of that residual stress is desired. It is shown in this paper that a flat aluminum specimen may be prepared with stress concentration discontinuities, and the part loaded so that the average stress and strain is below the yield point and the maximum stress in the discontinuity is beyond the yield point. Upon unloading from this condition, residual stresses will be present in the part, which may then be released by sawing through the part. Classical predictions of residual stress are correlated to a finite element model which simulates the loading, unloading, and cutting steps of the process. Observations on the difficulties inherent in experimentally accomplishing this process are also presented. Introduction Residual stresses are often present in physical parts. Mechanical action on finished parts and manufacturing operations of many types leave residual stresses. Two common examples are cold rolling of steel sheet, and cooling welds. Cold rolling significantly yields part of the material, but not uniformly through the thickness. Hence in a machining operation where one surface is removed, the part will warp to some degree, often quite visibly. Welds cool non-uniformly, leaving the portion which cools last in tension and the part which cools more quickly in compression. Weld distortion is a common result. For any case, residual stresses are present in the part and all operating stresses are added to the residuals present in the part. Since residual stress can affect the performance or life of