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Residual Stresses: and Their Effects On Fatigue Resistance
Residual Stresses: and Their Effects On Fatigue Resistance
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 1
RESIDUAL STRESSES AND THEIR EFFECTS ON
FATIGUE RESISTANCE
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 2
RESIDUAL STRESSES AND THEIR EFFECTS
ON FATIGUE RESISTANCE
EXAMPLES
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 3
EXAMPLES
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 4
S-N behavior of a Ni-Cr alloy steel
subjected to rotating bending
with three different surface
conditions involving
smooth (solid circles),
notched (x’s), and
notched shot-peened (open
squares) specimens.
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 6
PRODUCTION OF RESIDUAL
STRESSES & FATIGUE
RESISTANCE
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 7
PRODUCTION OF RESIDUAL STRESSES &
FATIGUE RESISTANCE
Mechanical Methods
Thermal Methods
Plating
Machining
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 8
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 9
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 10
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 11
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 12
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 13
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 14
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 15
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 16
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 17
MECHANICAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 18
MECHANICAL METHODS
Residual stresses are especially
valuable when used with harder
materials because the full
potential of greater yield
strength can be used only if the
damaging effect of notches can
be overcome.
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 20
THERMAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 21
THERMAL METHODS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 23
PLATING
Plating by electrolytic means can involve
soft plating materials such as zinc, tin, lead, or copper, or
harder plating materials such as chromium and nickel.
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 24
PLATING
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 25
PLATING
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 26
PLATING
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 28
MACHINING
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 29
MACHINING
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 30
MACHINING
Grinding also produces a wide
variation in residual stresses and
fatigue resistance.
Conventional, or abusive grinding,
using high speed, high feed, water
as lubricant, or no lubricant
introduce significant shallow, but
high magnitude, residual surface
tensile stresses.
Gentle grinding with low speed, low
feed, and oil as a lubricant can
provide shallow low magnitude
residual compressive surface
stresses.
Residual stress distributions for
gentle, conventional, and abusive
grinding are shown for 4340 Q&T
steel with Rc = 50.
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 31
RELAXATION OF RESIDUAL STRESSES
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 33
RELAXATION OF RESIDUAL STRESSES
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 35
MEASUREMENT OF RESIDUAL STRESS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 36
MEASUREMENT OF RESIDUAL STRESS
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 38
STRESS INTENSITY FACTORS FOR RESIDUAL STRESSES
KT = Kapplied + Kresidual
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 43
SUMMARY & DOS AND DON’TS IN DESIGN
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 45
SUMMARY & DOS AND DON’TS IN DESIGN
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 46
SUMMARY & DOS AND DON’TS IN DESIGN
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 47
SUMMARY & DOS AND DON’TS IN DESIGN
Ali Fatemi-University of Toledo All Rights Reserved Chapter 8 – Residual Stresses & Their Effects 48