Practical Residual Stress Measurement Methods.pdf

Practical Residual Stress Measurement Methods.pdf

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PRACTICALRESIDUALSTRESSMEASUREMENTMETHODSPRACTICALRESIDUALSTRESSMEASUREMENTMETHODSEditedbyGaryS.SchajerUniversityofBritishColumbia,Vancouver,CanadaAJohnWiley&Sons,Ltd.,PublicationThiseditionfirstpublished20132013JohnWiley&SonsLtdRegisteredofficeJohnWiley&SonsLtd,TheAtrium,SouthernGate,Chichester,WestSussex,PO198SQ,UnitedKingdomFordetailsofourglobaleditorialoffices,forcustomerservicesandforinformationabouthowtoapplyforpermissiontoreusethecopyrightmaterialinthisbookpleaseseeourwebsiteat.TherightoftheauthortobeidentifiedastheauthorofthisworkhasbeenassertedinaccordancewiththeCopyright,DesignsandPatentsAct1988.Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recordingorotherwise,exceptaspermittedbytheUKCopyright,DesignsandPatentsAct1988,withoutthepriorpermissionofthepublisher.Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbeavailableinelectronicbooks.Designationsusedbycompaniestodistinguishtheirproductsareoftenclaimedastrademarks.Allbrandnamesandproductnamesusedinthisbookaretradenames,servicemarks,trademarksorregisteredtrademarksoftheirrespectiveowners.Thepublisherisnotassociatedwithanyproductorvendormentionedinthisbook.LimitofLiability/DisclaimerofWarranty:

Whilethepublisherandauthorhaveusedtheirbesteffortsinpreparingthisbook,theymakenorepresentationsorwarrantieswithrespecttotheaccuracyorcompletenessofthecontentsofthisbookandspecificallydisclaimanyimpliedwarrantiesofmerchantabilityorfitnessforaparticularpurpose.Itissoldontheunderstandingthatthepublisherisnotengagedinrenderingprofessionalservicesandneitherthepublishernortheauthorshallbeliablefordamagesarisingherefrom.Ifprofessionaladviceorotherexpertassistanceisrequired,theservicesofacompetentprofessionalshouldbesought.LibraryofCongressCataloging-in-PublicationDataPracticalresidualstressmeasurementmethods/editedbyGaryS.Schajer.pagescmIncludesbibliographicalreferencesandindex.ISBN978-1-118-34237-4（hardback）1.Residualstresses.I.Schajer,GaryS.,editorofcompilation.TA648.3.P732013620.1123dc232013017380AcataloguerecordforthisbookisavailablefromtheBritishLibrary.ISBN9781118342374Setin10/12TimesbyLaserwordsPrivateLimited,Chennai,IndiaThisbookisdedicatedtothememoryofIainFinnielateProfessorofMechanicalEngineeringattheUniversityofCalifornia,Berkeley,apioneerdeveloperoftheSlittingMethodformeasuringresidualstresses.Respectfullydedicatedinappreciationofhisencouragement,teaching,mentorshipandpersonalfriendship.TheroyaltiesfromthesaleofthisbookhavebeendirectedtotheLeonardandLillySchajerMemorialBursaryattheUniversityofBritishColumbia,toprovidebursariestoMechanicalEngineeringstudentsonthebasisoffinancialneed.ContentsListofContributorsxvPrefacexvii1OverviewofResidualStressesandTheirMeasurement1GaryS.SchajerandClaytonO.Ruud1.1Introduction11.1.1CharacterandOriginofResidualStresses11.1.2EffectsofResidualStresses31.1.3ResidualStressGradients41.1.4DeformationEffectsofResidualStresses51.1.5ChallengesofMeasuringResidualStresses61.1.6ContributionofModernMeasurementTechnologies71.2RelaxationMeasurementMethods71.2.1OperatingPrinciple71.3DiffractionMethods131.3.1MeasurementConcept131.3.2X-rayDiffraction141.3.3SynchrotronX-ray151.3.4NeutronDiffraction151.4OtherMethods161.4.1Magnetic161.4.2Ultrasonic171.4.3Thermoelastic171.4.4Photoelastic181.4.5Indentation181.5PerformanceandLimitationsofMethods181.5.1GeneralConsiderations181.5.2PerformanceandLimitationsofMethods191.6StrategiesforMeasurementMethodChoice191.6.1FactorstobeConsidered191.6.2CharacteristicsofMethods24References24viiiContents2HoleDrillingandRingCoring29GaryS.SchajerandPhilipS.Whitehead2.1Introduction292.1.1IntroductionandContext292.1.2History302.1.3DeepHoleDrilling312.2DataAcquisitionMethods312.2.1StrainGages312.2.2OpticalMeasurementTechniques332.3SpecimenPreparation352.3.1SpecimenGeometryandStrainGageSelection352.3.2SurfacePreparation382.3.3StrainGageInstallation402.3.4StrainGageWiring402.3.5InstrumentationandDataAcquisition412.4HoleDrillingProcedure422.4.1DrillingCutterSelection422.4.2DrillingMachines432.4.3OrbitalDrilling442.4.4IncrementalMeasurements452.4.5Post-drillingExaminationofHoleandCutter462.5ComputationofUniformStresses472.5.1MathematicalBackground472.5.2DataAveraging492.5.3PlasticityEffects502.5.4RingCoreMeasurements502.5.5OpticalMeasurements502.5.6OrthotropicMaterials502.6ComputationofProfileStresses512.6.1MathematicalBackground512.7ExampleApplications542.7.1Shot-peenedAlloySteelPlateApplicationoftheIntegralMethod542.7.2NickelAlloyDiscFineIncrementDrilling542.7.3TitaniumTest-piecesSurfaceProcesses562.7.4CoatedCylinderBoreAdaptationoftheIntegralMethod572.8PerformanceandLimitationsofMethods572.8.1PracticalConsiderations572.8.2CommonUncertaintySources582.8.3TypicalMeasurementUncertainties59References613DeepHoleDrilling65DavidJ.Smith3.1IntroductionandBackground65Contentsix3.2BasicPrinciples683.2.1ElasticAnalysis683.2.2EffectsofPlasticity713.3ExperimentalTechnique723.4ValidationofDHDMethods753.4.1TensileLoading753.4.2ShrinkFittedAssembly773.4.3PriorElasticplasticBending783.4.4QuenchedSolidCylinder793.5CaseStudies803.5.1WeldedNuclearComponents803.5.2ComponentsfortheSteelRollingIndustry823.5.3FibreComposites823.6SummaryandFutureDevelopments83Acknowledgments84References854TheSlittingMethod89MichaelR.Hill4.1MeasurementPrinciple894.2ResidualStressProfileCalculation904.3StressIntensityFactorDetermination964.4PracticalMeasurementProcedures964.5ExampleApplications994.6PerformanceandLimitationsofMethod1014.7Summary106References1065TheContourMethod109MichaelB.PrimeandAdrianT.DeWald5.1Introduction1095.1.1ContourMethodOverview1095.1.2BuecknersPrinciple1105.2MeasurementPrinciple1105.2.1IdealTheoreticalImplementation1105.2.2PracticalImplementation1105.2.3AssumptionsandApproximations1125.3PracticalMeasurementProcedures1145.3.1PlanningtheMeasurement1145.3.2Fixturing1145.3.3CuttingthePart1155.3.4MeasuringtheSurfaces1165.4ResidualStressEvaluation1175.4.1BasicDataProcessing1175.4.2AdditionalIssues120xContents5.5ExampleApplications1215.5.1ExperimentalValidationandVerification1215.5.2UniqueMeasurements1275.6PerformanceandLimitationsofMethods1305.6.1NearSurface（Edge）Uncertainties1305.6.2SizeDependence1315.6.3SystematicErrors1315.7FurtherReadingOnAdvancedContourMethodTopics1335.7.1SuperpositionForAdditionalStresses1335.7.2CylindricalParts1345.7.3Miscellaneous1345.7.4Patent134Acknowledgments134References1356AppliedandResidualStressDeterminationUsingX-rayDiffraction139ConalE.MurrayandI.CevdetNoyan6.1Introduction1396.2MeasurementofLatticeStrain1416.3AnalysisofRegulardvs.sin2Data1436.3.1Dolle-HaukMethod1436.3.2Winholtz-CohenLeast-squaresAnalysis1436.4CalculationofStresses1456.5EffectofSampleMicrostructure1466.6X-rayElasticConstants（XEC）1496.6.1ConstitutiveEquation1506.6.2GrainInteraction1516.7Examples1536.7.1Isotropic,BiaxialStress1536.7.2TriaxialStress1546.7.3Single-crystalStrain1566.8ExperimentalConsiderations1596.8.1InstrumentalErrors1596.8.2ErrorsDuetoCountingStatisticsandPeak-fitting1596.8.3ErrorsDuetoSamplingStatistics1596.9Summary160Acknowledgments160References1607SynchrotronX-rayDiffraction163PhilipWithers7.1BasicConceptsandConsiderations1637.1.1Introduction1637.1.2ProductionofX-rays;Undulators,Wigglers,andBendingMagnets1667.1.3TheHistoricalDevelopmentofSynchrotronSources167Contentsxi7.1.4PenetratingCapabilityofSynchrotronX-rays1697.2PracticalMeasurementProceduresandConsiderations1697.2.1DefiningtheStrainMeasurementVolumeandMeasurementSpacing1707.2.2FromDiffractionPeaktoLatticeSpacing1737.2.3FromLatticeSpacingtoElasticStrain1737.2.4FromElasticStraintoStress1787.2.5ThePrecisionofDiffractionPeakMeasurement1797.2.6Reliability,SystematicErrorsandStandardization1807.3Angle-dispersiveDiffraction1847.3.1ExperimentalSet-up,Detectors,andDataAnalysis1847.3.2Exemplar:

MappingStressesAroundForeignObjectDamage1867.3.3Exemplar:

FastStrainMeasurements1877.4Energy-dispersiveDiffraction1887.4.1ExperimentalSet-up,Detectors,andDataAnalysis1897.4.2Exemplar:

CrackTipStrainMappingatHighSpatialResolution1897.4.3Exemplar:

MappingStressesinThinCoatingsandSurfaceLayers1907.5NewDirections1917.6ConcludingRemarks192References1938NeutronDiffraction195ThomasM.Holden8.1Introduction1958.1.1MeasurementConcept1958.1.2NeutronTechnique1968.1.3NeutronDiffraction1968.1.43-DimensionalStresses1988.1.5NeutronPathLength1988.2Formulation1998.2.1DeterminationoftheElasticStrainsfromtheLatticeSpacings1998.2.2RelationshipbetweentheMeasuredMacroscopicStraininagivenDirectionandtheElementsoftheStrainTensor1998.2.3RelationshipbetweentheStressi,jandStraini,jTensors2008.3NeutronDiffraction2018.3.1PropertiesoftheNeutron2018.3.2TheStrengthoftheDiffractedIntensity2028.3.3CrossSectionsfortheElements2038.3.4Alloys2048.3.5DifferenceswithRespecttoX-rays2058.3.6CalculationofTransmission205xiiContents8.4NeutronDiffractometers2068.4.1ElementsofanEngineeringDiffractometer2068.4.2MonochromaticBeamDiffraction2068.4.3Time-of-flightDiffractometers2098.5SettingupanExperiment2108.5.1ChoosingtheBeam-definingSlitsorRadialCollimators2108.5.2CalibrationoftheWavelengthandEffectiveZerooftheAngleScale,202108.5.3CalibrationofaTime-of-flightDiffractometer2108.5.4