Scribd Logo
Upload

Welcome to Scribd!

  • 59 views

    Residual Stress Measurements by Hole Drilling According To Astm E837 Standard

    Uploaded by

    JeanRosaOliveira
    The document discusses residual stress measurement using the hole drilling strain gage method according to ASTM E837 standards. It describes residual stresses, their causes, and measurement techniques. The hole drilling strain gage method is outlined as the most widely used technique and the instrument used can automatically perform measurements compliant with ASTM E837. Typical application fields are automotive, aerospace, oil and gas, and production control and example measurement results are shown for areas like cracks, welds, and shot peened surfaces.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Residual Stress Measurements by Hole Drilling According To Astm E837 Standard

    Uploaded by

    JeanRosaOliveira
    59 views26 pages
    The document discusses residual stress measurement using the hole drilling strain gage method according to ASTM E837 standards. It describes residual stresses, their causes, and measurement techniques. The hole drilling strain gage method is outlined as the most widely used technique and the instrument used can automatically perform measurements compliant with ASTM E837. Typical application fields are automotive, aerospace, oil and gas, and production control and example measurement results are shown for areas like cracks, welds, and shot peened surfaces.

    Original Title

    61-Residual_Stress_Hole_Drilling.pdf

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses residual stress measurement using the hole drilling strain gage method according to ASTM E837 standards. It describes residual stresses, their causes, and measurement techniques. The hole drilling strain gage method is outlined as the most widely used technique and the instrument used can automatically perform measurements compliant with ASTM E837. Typical application fields are automotive, aerospace, oil and gas, and production control and example measurement results are shown for areas like cracks, welds, and shot peened surfaces.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    59 views26 pages

    Residual Stress Measurements by Hole Drilling According To Astm E837 Standard

    Uploaded by

    JeanRosaOliveira
    The document discusses residual stress measurement using the hole drilling strain gage method according to ASTM E837 standards. It describes residual stresses, their causes, and measurement techniques. The hole drilling strain gage method is outlined as the most widely used technique and the instrument used can automatically perform measurements compliant with ASTM E837. Typical application fields are automotive, aerospace, oil and gas, and production control and example measurement results are shown for areas like cracks, welds, and shot peened surfaces.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 26

    Via Delle Calandre 63

    50041 Calenzano (Florence) – Italy


    Tel: +39.055.8826-302 – Fax: -303
    www.sintechnology.com
    [email protected]

    RESIDUAL STRESS MEASUREMENTS BY HOLE


    DRILLING ACCORDING TO ASTM E837 STANDARD
    PRESENTATION CONTENTS

    • What are residual stresses

    • Residual stress causes

    • RS measuring methods with strain gages

    • The hole-drilling strain-gage method

    • The standard ASTM E837

    • The instrument used for the measurements

    • Typical application fields

    • Typical measurement results

    Residual Stress Hole Drilling 2


    What are residual stresses
    All stresses that occur in the materials, also without the application of any external load,
    are termed residual stresses
    Residual stresses influence a mechanical component’s behaviour as they:
     Affect structural and dimensional stability
     Reduce fatigue strength and crack resistance
     Encourage surface crack growth

    Residual stresses therefore limit load


    capacity and safety of mechanical
    components during operation

    Residual Stress Hole Drilling 3


    Residual stress causes

    Residual stresses can be caused by several main factors:

     Fabrication process (forging, welding)  Machining process (turning)

     Heat treatments (quenching)  Surface treatments (shot peening)

    Residual Stress Hole Drilling 4


    Residual stress measuring methods with strain gages

    Hole
    Drilling

    Ring Coring

    Slitting

    Sectioning /
    Layer removal

    Sach’s boring

    Residual Stress Hole Drilling 5


    The hole-drilling strain-gage method

    The hole-drilling strain-gage method is the most widely used method for
    measuring residual stresses, for several reasons:
    • Very simple

    • Low cost of the machine (and of the test when using an automatic system)

    • Possibility to elaborate the results up to at least 1mm in a very fast way

    • High availability of strain gages and accessories for the measurement

    • Compliant to ASTM E837, the only complete standard on RS


    measurements available in the world
    • Availability of AUTOMATIC MACHINE with very high resolution and
    accuracy thanks to the complete control of all the measurement parameters

    Residual Stress Hole Drilling 6


    The hole-drilling strain-gage method

    The hole-drilling strain-gage method consists in drilling a small hole (approx.


    1.8 mm x 2.0 mm) into the centre of a 3-element strain rosette with suitable drill
    bits and a special air turbine (400,000 RPM)

    The hole changes the initial strain allowing redistribution of the


    residual stresses originally existing in the material

    Φ 1.8
    mm

    2 mm

    Residual Stress Hole Drilling 7


    Hole-drilling strain-gage method to ASTM E837

    The hole-drilling strain-gage method is the only method for calculating residual stress
    that is STANDARDIZED at world level (ASTM E837)
    The first version of this standard dates back to 1995, the latest upgrade is available from
    the end of 2013

    Standard ASTM E837 specifies:


     The number of drilling increments required
     The numerical coefficients for determining the value of residual stresses
     The data processing method
     The measurement-related uncertainty

    Residual Stress Hole Drilling 8


    Hole-drilling strain-gage method to ASTM E837-13

    Different types of holes, based on the workpiece thickness:

    THROUGH HOLE - THIN WORKPIECE


    Workpiece thickness < 0.2·DGAGE (std. 1mm)

    stresses are considered uniform over


    the drilling depth

    INTERMEDIATE HOLE
    Workpiece thickness between 0.2·DGAGE e DGAGE (std. between 1mm and 5mm)

    THROUGH HOLE INTERMEDIATE HOLE


     Drilling depth: entire thickness  Approximate results
     Stresses are assumed to be uniform  The elaboration of the test result is
     Acquisition of a set of 3 strain values outside the scope of the ASTM E837-13
    once the through hole is completed standard

    Residual Stress Hole Drilling 9


    Hole-drilling strain-gage method to ASTM E837

    BLIND HOLE (Typical) – THICK WORKPIECE


    Workpiece thickness > DGAGE (std. 5mm)

    UNIFORM STRESSES NOT UNIFORM STRESSES


     Drilling depth: 0.2 · DGAGE (std 1mm)  Drilling depth: 0.2 · DGAGE (std 1mm)
     Stress value over the drilling depth  Residual stress pattern over the drilling depth
     10 drilling steps of 0.02 · DGAGE (std  20 drilling steps of 0.01 · DGAGE (std 0.05 mm)
    0.1 mm)  Evolution of the “old” Integral Method

    A “uniform stress” calculation is appropriate when prior information is available, for


    example, based on workpiece geometry or processing procedure.
    Another purpose of doing a uniform stress calculation is to determine a representative
    size of the residual stresses that are present.

    Residual Stress Hole Drilling 10


    The instrument used for the measurements

    The MTS3000 system is the only fully AUTOMATIC and portable instrument in the
    world for determining residual stress by the hole-drilling strain-gage method

    The MTS3000 system consists of:


     A mechanical setup housing the optical system and drilling system
     An electronic control unit
     A digital strain gage amplifier
     Control and back-calculation software

    Residual Stress Hole Drilling 11


    The instrument: measuring chain

    Residual Stress Hole Drilling 12


    The instrument: main advantages

    Chief advantages in using


    an AUTOMATIC system:

     Higher repeatability of measurement  Shorter testing time


     Higher hole drilling accuracy  Fully compliant to ASTM E837 standard

    HIGHER PRODUCTIVITY REDUCTION IN COSTS

    Residual Stress Hole Drilling 13


    The instrument: fields of application
    The MTS3000 system can be used to determine residual stresses on a wide variety of
    materials, such as:
     Standard metals (e.g. Steel, Aluminum, Cast iron)
     Non-standard metals (e.g. Titanium, High Tensile Steels)
     Plastics (e.g. ABS, Polycarbonate)
     Composites

     Air turbine (standard)


    CHOICE OF CONFIGURATION
     Electric motor (plastics, composites)

     Feed rate
    CHOICE OF CUTTING AND
     Rotational speed
    RECORDING PARAMETERS
     Delay time

     Tungsten carbide
    CHOICE OF TYPE OF CUTTER  Tungsten carbide with coatings
     Diamond

    Residual Stress Hole Drilling 14


    Hole drilling: typical application fields
    • In 95% of the cases, the stresses are NOT uniform with the depth

    • It’s difficult to measure residual stresses without a suitable machine because of the lower
    precision of these instrument in the detection of the starting point and of the step/total
    depth: this situation can lead to big errors in the post-elaboration of the results

    • Generally, it’s difficult to predict the residual stress value of a component BUT…

    • …In some typical application fields, it’s possible to have typical measurement results

    - Typical on-site measurements -


    Residual Stress Hole Drilling 15
    Typical measurement results: Automotive
    • Cracked area

    Residual Stress Hole Drilling 16


    Typical measurement results: Automotive
    • Cracked area

    Residual Stress Hole Drilling 17


    Typical measurement results: Aerospace
    • Stress-relieved welding area

    Residual Stress Hole Drilling 18


    Typical measurement results: Aerospace
    • Stress-relieved welding area

    Residual Stress Hole Drilling 19


    Typical measurement results: Oil & Gas
    • Shot-peened area

    Residual Stress Hole Drilling 20


    Typical measurement results: Oil & Gas
    • Shot-peened area

    Residual Stress Hole Drilling 21


    Typical measurement results: Production control
    • Welding area

    Residual Stress Hole Drilling 22


    Typical measurement results: Production control
    • Welding area

    Residual Stress Hole Drilling 23


    Typical measurement results: Production control
    • Before & after stress-relieving heat treatment

    Residual Stress Hole Drilling 24


    Typical measurement results: Production control
    • Before & after stress-relieving heat treatment

    Residual Stress Hole Drilling 25


    Via Delle Calandre 63- 50041 Calenzano (Florence) – Italy
    Tel: +39.055.8826-302 – Fax: -303
    www.sintechnology.com
    [email protected]

    You might also like