MTS3000: Automatic system for determining residual stresses

by the strain-gage method

RESIDUAL STRESS
CALCULATION USING
MTS3000 RESTAN
Automatic system for determining residual
stresses by the strain-gage method
SINT Technology srl

Via Giusti, 229

50041 Calenzano (Florence) Italy
Tel: +39.055.8826-302 Fax: -303
Web: www.sintechnology.com
e-mail: info@sintechnology.com

Development of MTS3000 RESTAN system

Calculation method

The main calculation method for hole drilling measurements

implemented in SINT EVAL software vers. 5 are:

ASTM E837-08 for uniform stress field

ASTM E837-08 for not uniform stress field

Integral method

Schwarz-Kochelmann method.

ANALYSIS
METHODS

UNIFORM STRESSES
OVER THE DEPTH
NOT UNIFORM
STRESSES OVER THE
DRILLING DEPTH

ASTM E837-08
ASTM E837-08
Integral Method
Kockelmann method

Development of MTS3000 RESTAN system

Measurement of the strains

The first operation to carry out for obtaining a

good calculation of residual stress is the correct
acquisition of the strains.
MTS3000 system allows to automatically configure
the measurement chain using all the HBM rosettes
and using the HBM strain gage amplifiers Spider
8.30 and MGCPlus.
SINT Eval software allows to
realize an optimized polinomial
interpolation of the input strains.

Hole drilling strain gage method to ASTM E837-08

Hole drilling strain gage method to ASTM E837-08

The hole-drilling strain-gage method is the only method for calculating residual
stress that is STANDARDIZED at world level (standard ASTM E837-08).
The first version of this standard dates back to 1995.

Standard ASTM E837-08 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.

Hole drilling strain gage method to ASTM E837-08

Hole drilling strain gage method to ASTM E837-08

THROUGH HOLE

Workpiece thickness < 0.4DGAGE (std. 2.0 mm)

INTERMEDIATE HOLE

Workpiece thickness between 0.4DGAGE

e 1.2DGAGE (std. between 2.0 mm and 6.1 mm)
STRESSES ARE CONSIDERED UNIFORM OVER THE DRILLING DEPTH
THROUGH HOLE

Drilling depth: entire thickness

of the specimen
Stresses are assumed uniform
over the drilling depth
Acquisition of a set of three
strains once the through hole
is completed.

INTERMEDIATE HOLE

Drilling depth: 2 mm

Uniform stress value over 2

mm of thickness
8 drilling steps of 0.05 DGAGE
(standard 0.25 mm)
Approximate results.

Hole drilling strain gage method to ASTM E837-08

Hole drilling strain gage method to ASTM E837-08

BLIND HOLE

Workpiece thickness > 1.2DGAGE (std. 6.1 mm)

UNIFORMITY TEST

Stresses are considered uniform over the

drilling depth provided strains do not deviate
from the curves provided by 3%.

UNIFORM
STRESSES

NOT UNIFORM
STRESSES

Drilling depth: 2 mm

Drilling depth: 2 mm

Uniform stress value over 2

mm of thickness

Residual stress pattern in 1 mm

of depth

8 drilling steps of 0.05 DGAGE

(standard 0.25 mm).

40 drilling steps of 0.05 mm

Evolution
method.

of

the

Integral

Hole drilling strain gage method to ASTM E837-08

Calculation of a, b coefficients for HBM rosettes

SINT Technology has realized the calculation of a, b coefficients for all the types
of HBM rosettes.
The standard ASTM E837-08 tales into account hole drilling rosettes with different
sizes (like average grid radius, length and height).

Using the EVAL software,

you can automatically
detect the strain gage
rosettes that you are
using and perform a
correct back-calculation
of residual stress.

1-RY61-1.5/120S - Coefficient a

1-RY61-1.5/120S - Coefficient b

Development of MTS3000 RESTAN system

Integral method

Integral method for residual stress analysis was

proposed by G. S. Schajer in 1988 in order to
overcome the limits of ASTM standard regarding
the constant stress field.

The systems software allows you to select number

and distribution of the depth increments, while in
the Non-Uniform Stress Method these parameters
are fixed by the ASTM standard.

The maximum calculation depth is 0.5 times the

mean radius of the strain rosettes used for the
test.
The integral method should be chosen when residual
stresses are expected to vary significantly with depth;
however, it also has the highest sensitivity to test
errors.

Development of MTS3000 RESTAN system

Integral method

Integral method: computation of non-uniform stress

Integral method: computation of non-uniform stress

MIN
[MPa]
-130.5
-471.0
-699.3
-877.1
-1011.4
-1109.2
-1176.8
-1219.7
-1242.0
-1247.6
-1239.3
-1219.6
-1190.5
-1153.4
-1109.8
-1060.5
-1006.6
-948.8
-887.8
-824.2
-758.6
-691.7
-624.2
-557.0
-491.3
-426.2
-371.3
-263.7
-157.1
-52.1
24.3
106.5
176.8
221.1
238.6
213.5
227.2
223.5
288.2
347.5
338.3
321.4
247.7
205.0
207.7

Depth
[mm]
0.005
0.015
0.025
0.035
0.045
0.055
0.065
0.075
0.085
0.095
0.105
0.115
0.125
0.135
0.145
0.155
0.165
0.175
0.185
0.195
0.205
0.215
0.225
0.235
0.245
0.263
0.287
0.312
0.338
0.362
0.388
0.412
0.437
0.463
0.487
0.525
0.575
0.625
0.675
0.725
0.775
0.825
0.875
0.925
0.975

MAX
[MPa]
21.6
-138.5
-283.4
-396.4
-484.3
-551.8
-602.6
-639.6
-665.2
-681.4
-689.7
-691.4
-687.7
-679.2
-666.7
-650.7
-631.4
-609.2
-584.3
-556.8
-526.8
-494.2
-459.0
-420.8
-379.2
-336.6
-273.4
-139.6
-8.8
107.2
170.1
252.4
320.9
379.2
429.1
480.2
571.6
599.7
677.5
725.4
719.0
749.2
744.3
816.7
951.9

15 mm

Point 1

Point 2

x (AXIAL)
[MPa]
-14.7
-189.4
-325.2
-433.4
-518.2
-583.4
-632.2
-667.3
-690.9
-705.0
-711.2
-710.7
-704.6
-693.8
-678.9
-660.5
-639.0
-614.6
-587.8
-558.7
-527.4
-494.2
-459.2
-422.5
-384.4
-357.3
-313.7
-216.0
-111.4
-5.1
77.7
173.3
265.0
344.1
408.3
471.4
568.4
599.2
677.4
724.6
717.8
748.3
744.1
816.4
951.7

xy
[MPa]
-74.0
-166.2
-205.9
-234.4
-253.9
-265.9
-271.9
-272.9
-269.9
-263.6
-254.5
-243.2
-230.0
-215.2
-199.2
-182.3
-164.5
-146.3
-127.7
-108.9
-90.2
-71.8
-53.7
-36.2
-19.4
9.6
27.9
52.8
68.5
74.5
63.5
55.7
38.3
15.4
-10.5
-54.5
-96.2
-123.2
-141.3
-145.7
-149.0
-164.1
-183.4
-224.5
-272.1

VonMises
[MPa]
142.6
419.3
609.2
760.8
876.1
960.6
1019.3
1056.7
1076.5
1082.0
1075.6
1059.4
1035.1
1004.1
967.6
926.3
881.1
832.7
781.6
728.3
673.3
617.1
560.2
502.9
446.0
389.2
333.3
228.5
152.9
140.7
159.4
219.4
278.4
329.9
372.4
416.7
498.5
524.9
588.9
628.4
623.1
651.0
656.5
735.9
866.9

Axial direction

40 mm

700.0

-100.0
0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

1.000

-500.0

Residual stresses [MPa]

1100.0

700.0
300.0

-900.0

-1300.0

700.0

700.0

300.0

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.100

0.200

0.300

0.400

0.900

1.000

-500.0
-900.0

0.500

y (TANGENTIAL)
[MPa]
-149.2
-429.0
-597.9
-727.7
-826.4
-900.5
-955.2
-994.5
-1021.8
-1039.2
-1048.7
-1051.3
-1048.0
-1039.3
-1025.5
-1006.7
-983.1
-954.7
-921.5
-883.5
-841.0
-794.1
-743.0
-688.0
-629.5
-581.0
-496.9
-338.9
-176.0
-18.9
94.9
206.1
308.3
385.6
438.3
464.6
538.1
558.6
659.4
747.8
769.2
789.1
649.1
433.4
217.5

0.600

0.700

MIN

Depth [mm]
1100.0

0.100

x (AXIAL)
[MPa]
-281.2
-546.7
-686.2
-790.9
-868.1
-923.3
-961.1
-984.8
-997.2
-1000.2
-995.3
-983.8
-966.4
-943.8
-916.6
-885.1
-849.8
-811.0
-768.9
-724.0
-676.6
-626.9
-575.4
-522.5
-468.4
-430.1
-369.1
-247.9
-126.8
-10.5
61.4
157.7
248.1
325.0
386.6
435.1
525.3
543.1
626.4
725.8
799.4
884.5
748.1
465.9
221.6

VonMises

1100.0

-100.0
0.000

[]
-57.2
-73.8
-81.1
-84.7
-86.9
-88.4
-89.6
89.4
88.5
87.6
86.7
85.8
84.8
83.9
83.0
82.0
81.1
80.2
79.4
78.6
77.9
77.2
76.6
76.2
75.8
75.6
76.5
77.9
81.0
87.7
-77.3
-66.3
-52.6
-42.5
-34.1
-26.2
-12.5
-45.4
-74.5
-85.8
86.6
81.5
79.9
84.8
88.9

xy
[MPa]
25.4
-24.0
-65.8
-97.5
-121.2
-138.9
-152.1
-162.0
-169.5
-175.3
-180.0
-183.9
-187.1
-189.7
-191.7
-193.1
-193.8
-193.7
-192.6
-190.4
-187.1
-182.6
-176.9
-170.0
-161.8
-150.6
-133.9
-103.4
-70.9
-39.6
-13.1
1.3
15.6
23.3
25.6
18.5
14.2
5.4
-7.8
-44.7
-99.6
-143.8
-130.2
-73.6
-39.5

VonMises
[MPa]
249.1
523.7
688.9
815.9
911.0
980.6
1029.9
1063.2
1083.8
1094.3
1096.6
1092.0
1081.5
1065.8
1045.3
1020.4
991.1
957.8
920.4
879.2
834.2
785.7
734.0
679.2
621.9
574.0
496.9
350.4
204.8
91.2
103.3
190.6
283.4
359.2
415.3
451.0
532.3
551.0
645.3
748.2
814.4
883.0
741.4
475.5
238.6

0.800

0.900

1.000

-500.0

-900.0

MAX

MAX
[MPa]
-142.7
-378.0
-497.9
-587.0
-653.9
-703.8
-740.1
-765.5
-781.8
-790.4
-792.5
-788.8
-779.8
-765.9
-747.6
-725.0
-698.5
-668.4
-634.8
-598.1
-558.7
-516.8
-472.9
-427.2
-380.2
-348.7
-292.2
-182.9
-71.8
37.3
117.1
214.8
309.4
385.7
440.3
468.4
546.8
558.6
675.0
811.8
911.0
999.6
842.0
538.9
273.4

300.0
-100.0
0.000

-1300.0
MIN

MIN
[MPa]
-287.7
-597.7
-786.2
-931.7
-1040.6
-1120.0
-1176.1
-1213.9
-1237.2
-1249.0
-1251.5
-1246.3
-1234.7
-1217.2
-1194.5
-1166.8
-1134.4
-1097.3
-1055.6
-1009.4
-958.9
-904.2
-845.5
-783.2
-717.7
-662.5
-573.7
-404.0
-231.0
-66.6
39.1
149.0
247.0
324.9
384.6
431.2
516.6
543.1
610.7
661.8
657.6
674.0
555.1
360.4
165.7

Depth
[mm]
0.005
0.015
0.025
0.035
0.045
0.055
0.065
0.075
0.085
0.095
0.105
0.115
0.125
0.135
0.145
0.155
0.165
0.175
0.185
0.195
0.205
0.215
0.225
0.235
0.245
0.263
0.287
0.312
0.338
0.362
0.388
0.412
0.437
0.463
0.487
0.525
0.575
0.625
0.675
0.725
0.775
0.825
0.875
0.925
0.975

1100.0

Depth [mm]

Residual stresses [MPa]

y (TANGENTIAL)
[MPa]
-94.2
-420.1
-657.5
-840.1
-977.4
-1077.5
-1147.2
-1192.0
-1216.3
-1223.9
-1217.8
-1200.4
-1173.5
-1138.9
-1097.6
-1050.7
-999.1
-943.4
-884.3
-822.3
-757.9
-691.6
-623.9
-555.3
-486.2
-405.6
-331.0
-187.3
-54.5
60.2
116.8
185.5
232.7
256.3
259.5
222.2
230.4
224.0
288.2
348.4
339.5
322.2
247.9
205.2
207.9

Residual stresses [MPa]

Residual stresses [MPa]

Tangential direction

[]
74.2
68.0
63.5
61.1
59.7
58.8
58.1
57.6
57.2
56.8
56.4
56.0
55.6
55.1
54.5
53.9
53.1
52.2
51.1
49.8
48.1
45.8
42.8
38.6
32.6
16.3
5.1
-6.7
-11.3
-12.1
-7.8
-2.4
6.5
16.9
25.7
34.6
39.5
43.0
45.8
47.7
48.3
47.6
46.3
46.1
46.0

MAX

VonMises

300.0
-100.0
0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

1.000

-500.0
-900.0

-1300.0
Depth [mm]
Head of residual stresses area
Ing. Alessio Benincasa

x (AXIAL)

y (TANGENTIAL)

xy

-1300.0
Depth [mm]

Test Owner
Ing. Lorenzo Bertelli

Head of residual stresses area

Ing. Alessio Benincasa

x (AXIAL)

y (TANGENTIAL)
Test Owner
Ing. Lorenzo Bertelli

xy

Development of MTS3000 RESTAN system

Tikhonov regularization

SINT EVAL software allows to use the Tikhonov regularization of calculated

residual stresses for ASTM E837-08 (not uniform) and for the integral method.
The regularization can be useful to reduce the influence of the input data errors
in the calculation.
Benchmark integral method - ASTM E837-08 for not uniform stress filed
320.0

315.0

Stress [MPa]

310.0

305.0

Integral method with Tikhonov

regolaritation

Integral method
300.0

True stress
ASTM E837-08

295.0

ASTM E837-08 with Tickonov

290.0
0.0

0.1

0.2

0.3

0.4

0.5

Depth [mm]

0.6

0.7

0.8

0.9

1.0

Development of MTS3000 RESTAN system

Schwarz-Kockelmann method

This method, proposed by H. Kockelmann in 1993 is based on the strain ratio

measured during the hole drilling.
Schwartz

Kochelmann
calculation
method
is
centered
experimental/numerical evaluation of calibration functions Kx and Ky.

on

the

This method uses the numerical coefficients calculated by Kockelmann and allows
you to reach a calculation depth equal to the hole diameter. It is a method which
has little sensitivity to the effects of test errors but it is valid only in a very
particular case of rosette diameter and hole diameter (dm/d0 = 3).

Recently, also coefficients for different values of D/D0 have been provided and
included in the SINT EVAL software.

MTS3000: Automatic system for determining residual stresses

by the strain-gage method

RESIDUAL STRESS
CALCULATION USING
MTS3000 RESTAN
Automatic system for determining residual
stresses by the strain-gage method
SINT Technology srl

Via Giusti, 229

50041 Calenzano (Florence) Italy
Tel: +39.055.8826-302 Fax: -303
Web: www.sintechnology.com
e-mail: info@sintechnology.com