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Measurement of residual-stress distribution by the incremental hole-drilling method

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Abstract

The hole-drilling method is widely used to measure residual stresses in mechanical components. Recent developments have shown that strains measured on the surface during an incremental drilling can be related to residual-stress distribution. Researchers throughout the world have proposed different calibration methods which lead to more or less accurate results.

The present paper discusses different approaches used. A new calibration method is proposed. We also show how finite-element analysis can be used to determine the correlation coefficients. The variation of the strains measured on the surface for each increment is due to, first, the residual stresses in the layer and, second, the change of the hole geometry. Most authors do not consider the latter aspect. Our results show that this causes a significant error in the experimental data. The finite-element method has been used to compute the coefficients for all types of strain-gage rosettes when the hole diameter is predetermined.

Another problem of the hole-drilling method is the selection of the drilling tool. Two systems have been studied: ultra-high-speed air turbine and conventional milling machine. The method has been applied on both shot-peened and water-quenched test specimens. The results are successfully compared with the bending-deflection and the X-ray method.

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Abbreviations

A, B :

calibration coefficients using the standard elasticity laws

Ain, Bin :

calibration coefficients for the geometryn and the loadingi

d :

hole diameter

E :

elastic constant

\(\vec h\) :

mean radial direction of the central grid

Δh :

increase in the depth of the hole

r :

radius, distance from the center of the rosette to any point on the gage center line

Uin :

displacement calculated by the finite-element method, for the geometryn and the loadingi

\(\bar Uin\) :

nondimensional displacement

X 1,X 2 :

principal directions

Z :

present depth of the hole

θ:

angle between the directionh of the lines of the central grid and X

σ1, σ2 :

principal stresses

ε′i, ε″i, ε′″i :

strain measured in three directions θ i , θ i + and θ i + ψ

ε ′ mn , ε ″ mn , ε″ ′ mn :

total strain measured on the surface after the hole is drilled to the depthh n (m in ε ′ mn stands for measured)

ε ′ n , ε ″ n , ε′ ε ″ n :

surface strain changes due to the release of stress in thenth layer only

ν:

Poisson's ratio

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Authors and Affiliations

  1. CETIM, 52 Avenue Felix Louat, F 60304, Senlis, France

    A. Niku-Lari (Doctor of Science), J. Lu (Engineer) & J. F. Flavenot (Engineer)

Authors
  1. A. Niku-Lari
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  2. J. Lu
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  3. J. F. Flavenot
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Niku-Lari, A., Lu, J. & Flavenot, J.F. Measurement of residual-stress distribution by the incremental hole-drilling method. Experimental Mechanics 25, 175–185 (1985). https://doi.org/10.1007/BF02328809

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  • DOI: https://doi.org/10.1007/BF02328809

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