ISSN 10526188, Journal of Machinery Manufacture and Reliability, 2014, Vol. 43, No. 5, pp. 389–392.

© Allerton Press, Inc., 2014.

Original Russian Text © M.G. Yakovlev, V.A. Gorelov, N.S. Merkulova, A.S. Kudrov, 2014, published in Problemy Mashinostroeniya i Nadezhnosti Mashin, 2014, No. 5,
pp. 47–51.

RELIABILITY, STRENGTH, AND WEAR RESISTANCE

OF MACHINES AND STRUCTURES

Study of the Influence of Residual Stresses on the Fatigue

Strength of Samples Made of Titanium and Nickel Alloys
M. G. Yakovleva, V. A. Gorelovb, N. S. Merkulovab, and A. S. Kudrovb
a
Blagonravov Mechanical Engineering Institute, Russian Academy of Sciences, Moscow
b
Research Institute of Technology and Engine Production Organization,
GasTurbine Engineering Research and Production Center “Salut,” Moscow
email: maxx81@list.ru
Received October 21, 2013

Abstract—In this paper, we compare the results of measurements of residual stresses and study the
influence of residual stresses on the fatigue strength of samples made of titanium and nickel alloys after
various types of treatment: turning with the use of various lubricatingcooling tools, grinding, and sur
face plastic strain operation.
DOI: 10.3103/S1052618814050203

It is known that the compressive residual stresses always contribute to the growth of the fatigue limit
[1], so many scientists are engaged in studying the issues of establishing correlations of methods and
regimes of processing of components with their physical and mechanical characteristics and the level of
residual stresses σres [2, 3]. Attempts are made to control the manufacturing process of parts with the help
of feedback between quality parameters of the surface layer (roughness, cold working, and residual
stresses) and processing regimes [4].
This article describes the influence of residual stresses on the fatigue strength of the samples of titanium
and nickel alloys used in the production of gas turbine engines (GTE) and manufactured by different tech
nologies. As a criterion of association, we selected an energy characteristic of the surface layer—the area
under the diagram of compressive residual stresses. We studied the influence of tensile residual stresses at
the surface with an occurrence depth b of no more than 10 μm (typical of many types of machining: turn
ing, grinding, heavy strengthening, etc.) on the relationship of the fatigue strength with residual stresses.

RESEARCH OF INFLUENCE OF LUBRICANTS ON RESIDUAL STRESSES

AND FATIGUE STRENGTH IN TURNING OF TITANIUM ALLOY VT9
Operations of turning and strengthening by surface plastic strain were compared in terms of the fatigue
strength and residual stresses after optimization of the applied lubricants in cutting [5]. We used: dry cut
ting, cooling by compressed air, ionized gaseous medium, emulsion (Rusoil 500), and cutting with the use
of microencapsulated lubricants. The studies were carried out on samples of titanium alloy VT9 obtained
by turning using the VK6 incisors in the regime: cutting speed 70 m/min, feed 0.15 mm/rev, and depth
1 mm.

Study of Residual Stresses

Residual stresses were measured by a wellestablished method based on complete liberation of the
detail (sample) section and removal of the studied surface layers of metal by etching aimed at measuring
the strains resulting from the removal of strained layers for the subsequent calculation of residual stresses.
This method was established by Prof. N.N. Davidenkov and developed on the basis of an automated com
plex MerKulON Tenzor3, which was established at the Research Institute of Technology and Engine
Production Organization.
The results of residual stress measurements after various treatments are shown in Fig. 1. It is seen that
the highest compressive residual stresses arise after the surface plastic strain, and in turning the highest
compressive stresses are achieved by using the emulsion and compressed air.

389
390 YAKOVLEV et al.

σres, МPа RESULTS OF FATIGUE TESTS

100 5 3 2 Research technique. As the fatigue limit, we took
0 maximum stresses acting on the surface of the studied
−100 samples, at which there is no destruction up to a pre
1 determined number of cycles. For the basis of the test
−300 for the samples of alloy VT9, we took a number N =
4 2 × 107 cycles. The results of the fatigue tests were rep
−500 6 resented in coordinates logσ–logN (Fig. 2). The
fatigue tests were carried out using a research complex
−700 P646. The fracture criterion for the sample consisted
in the oscillation frequency change by 3–7% depend
−900 ing on the conditions of the test. In that case, the test
0 10 20 30 40 50 60 70 80 90 100 was stopped and the sample was monitored to detect
b, μm cracks. In the absence of cracks the test was continued.
The studies were carried out with the use of a form
Fig. 1. Results of measurements of residual stresses
after: 1, cutting with emulsion (Rusoil 500); 2, cut of samples recommended as a standard for fatigue
ting with feed of microencapsulated lubricants; tests.
3, dry cutting; 4, cooling by compressed air; 5, ion The working part of the sample made of titanium
ized gas environment; 6, strengthening by alloy VT9 was treated using cutters equipped with VK6
microballs.
plates under different cutting conditions: a feed of
compressed air into the treatment zone at a pressure of
0.25 MPa; a feed of the liquid lubricant into the treat
ment zone; a feed of ionized compressed air into the
σ, МPа treatment zone (cutting with compensation); the use
of microencapsulated lubricant in cutting; and the use
of a dry cutting process with compensation and subse
800 6 quent shot peening.
Study results. The results of testing all the series of
alloy VT9 samples are presented in Fig. 2. The analysis
750 of the study results allows us to note the following: 1) it
5 is established that dry cutting with the feed of com
pressed air or liquid lubricant (Rusoil 500) into the
700 treatment zone provides approximately the same
4
3 fatigue limit σ of the VT9 alloy samples at a level of 650
2 MPa (Fig. 2, curves 3–5); cutting with the introduc
650 tion of ionized gas or microencapsulated lubricants
1 into the treatment zone provides the sample endur
ance at a level up to 618–625 MPa (Fig. 2, curves 2 and
10 5
N, cycles 10 7 3), only slightly reducing the fatigue limit by about
25–32 MPa. The cutting operation and subsequent
Fig. 2. Fatigue curves of VT9 alloy samples pro shot peening provided the endurance of the VT9 alloy
cessed in different conditions: 1, cutting with feed samples at a level of 760 MPa.
of microencapsulated lubricants; 2, cutting with Thus, the results of studying the residual stresses
gas lubricant; 3, dry cutting; 4, cutting with emul and the fatigue tests of the VT9 alloy samples treated
sion; 5, cutting with compressed air at P =
0.3 MPa; 6, sample cutting after processing with under various conditions followed by shot peening
compensation and subsequent shot peening. showed that the area of the compressive stress dia
grams, as well as the fatigue limit, is maximal after
treating by surface plastic strain. After turning with
lubricants (microcapsules), the area of the compressive stress diagram is minimal, as is the fatigue limit.
In other cases of treatment, the areas of the compressive stress diagrams, as well as the fatigue strength lim
its, are similar. This supports the hypothesis that there is a good correlation expressed as a dependency of
the area under the residual stress diagrams on the endurance limit of the samples.

Studies on Influence of Creep Feed Grinding on Residual Stresses

and Fatigue Strength when Treating the Blade Foot of Alloy ZhS6
One of the promising and highperformance methods of processing the engine blade foot is a creep
feed grinding operation. In many cases, strengthening after creep feed grinding is not provided, although

JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 43 No. 5 2014

 STUDY OF THE INFLUENCE OF RESIDUAL STRESSES 391

Table 1
Processing regime Strain amplitude Relative strain
Experiment
no. grinding speed, for N = 107 cycles, amplitude for
m/s
feed, mm/min grinding depth, mm 2a N = 107 cycles

1 15 0.44 1.25
50
2 35 0.47 1.34
1
3 15 0.49 1.4
400
4 35 0.44 1.25
5 15 0.35 1.0
50
6 35 0.46 1.31
4
7 15 0.48 1.37
400
8 35 0.37 1.06

Table 2
No. Strengthening regime Limits of endurance at N = 2 × 106, kg/mm2
1 Original group 27.5
2 Porcelain balls, 2 h 37.5
3 Steel balls, 1 h 37.5
4 Steel balls, double 40.0
5 Steel balls, 2 h 45.0

the reliability of blade fet, as well as the reliability of blade pens, provides the overall durability. Let us con
sider the optimization of operating parameters of creep feed grinding by the fatigue strength criterion, as
well as its relationship to residual stresses [6].
The table shows the experimental design for regimes of creep feed grinding of the samples in which the
study of residual stresses and fatigue strength was carried out.
Residual stresses. The analysis of axial residual stresses showed that they are compressing. Their value
on the surface varies from –20 to –600 MPa. All the diagrams have a subsurface maximum of compressive
stresses within –300 to –900 MPa at a depth of 10 μm and approach zero at a depth of 50–70 μm.
The analysis of tangential residual stresses showed that the surfaces in all the experiments have tangen
tial tensile stresses of 150–800 MPa, which at shallow depths (up to 10 μm) are transformed into compres
sive. The compressive tangential stresses have a subsurface maximum –200 to –700 MPa at a depth of 10–
15 μm and approach zero at 30–50 μm.
Fatigue strength tests. The fatigue strength tests of the samples subjected to symmetrical alternating
bending were carried out with the electric vibrator VDS1500M at the pitch frequency at a temperature of
700°С. The results of the tests were compared in terms of the largest amplitude (strain) of their end sec
tions measured by the optical cathetometer KM8.
The test base consisted of N = 2 × 107 cycles. Upon passing the test base without breaking, the sample
was reloaded to the next level of stresses +Δ(2а) and, thus, brought to destruction.
The test results were estimated by the level of destruction and the number of cycles before destruction
at this level. The fatigue test results are shown in Table 1 (2a is the value of strain amplitude at the end sec
tions of the samples). The analysis of the results showed that the difference in the endurance limits
between experiments 1–4 is 10%: minimum limits of endurance occur in experiments 1 and 4, and they
are the same, while the maximum value was recorded in experiment 3. The comparison of the endurance
limits between experiments 5–8 shows that the minimum value of the endurance limit was obtained for
experiment 5, its value was slightly higher (~ by 6% percent) in experiment 8, and the maximum values of
experiment 5 were, respectively, 1.31 and 1.37 times. The comparison of all the investigated variants shows
that changes in the cutting conditions largely affect the samples treated with a 4 mm depth of cutting
(experiments 5–8).

JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 43 No. 5 2014

392 YAKOVLEV et al.

σres, МPа Because of the occurrence of tensile residual

50 stresses after creep feed grinding at the sample surface,
1 it was not possible to determine the relationship of
0
residual stresses with the fatigue strength.
−50 2 4
−100 3
−150 5 Influence of Strengthening Regimes on Residual Stresses,
Fatigue Strength, and Their Relationship
−200
when Processing Samples of Nickel Alloy Used
−250 in the Production of Gas Turbine Engine Blades
0 20 60 b, μm 100
The experiments were carried out on sleeves of
Fig. 3. Averaged diagrams of residual stresses in heatresistant nickel alloy KhN35VTYu, which were
samples of heatresistant nickel alloy after various
types of processing: 1, heat treatment at T =
obtained by cold rolling followed by finishing treat
ment by various technologies [2]: (1) heat treatment at
1050°C; 2, vibratory finishing by steel balls for 1 h
temperature Т = 1050°C; (2) vibratory finishing by
after heat treatment at T = 970°C; 3, vibratory fin
ishing by porcelain balls for 2 h after heat treatment
steel balls for 1 h after heat treatment at T = 970°C;
at T = 1050°C; 4, double vibratory finishing by (3) vibratory finishing by porcelain balls for 2 h after
steel balls after heat treatment at T = 1050°C;
heat treatment at T = 1050°C; (4) double vibratory fin
5, vibratory finishing by steel balls for 2 h after heat
treatment at T = 1050°C. ishing by steel balls after heat treatment at Т = 1050°C;
(5) vibratory finishing by steel balls for 2 h after heat
treatment at Т = 1050°C.
After the treatment, residual stresses were measured in the samples cut from the sleeves (Fig. 3).
The experimental data on the cyclic strength of the sleeves at the room temperature are shown in
Table 2.
Among the five finishing regimes studied, the fourth regime was recognized the best since it led to an
increase in the fatigue limit by 63% relative to the lot of heattreated samples after their cold rolling. Also,
it is characterized by the maximum area under the compressive residual stress diagrams.

FINDINGS
Tensile residual stresses, which emerge at the surface even with a small occurrence depth (less than
10 μm), reduce the fatigue strength of the samples and the degree of their relationship with the fatigue
strength of products.
For different types of treatment of titanium and nickel construction materials, we identified and proved
the correlation of the surface compressive residual stresses with the fatigue limit: the growth of the com
pressive stress diagram area causes the growth of the fatigue strength limit.

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Translated by K. Lazarev

JOURNAL OF MACHINERY MANUFACTURE AND RELIABILITY Vol. 43 No. 5 2014