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Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology, 2009 / Sophisticated measurement methods are currently used extensively to determine the residual stresses in materials. The capabilities of the Hole-Drilling Method, Debro-30 Ultrasonic System and Digital Shearography to determine residual stresses have been explored. The accuracy of these techniques in measuring residual stresses in mild steel specimens is thoroughly examined and discussed. The results obtained from the experiments are consistent with the expected outcomes. Related literature review, experimental procedures, results and their discussion have been outlined. It is hoped that the information provided in this thesis will be of importance to end users, especially engineers and technologists who use these non-destructive methods to evaluate residual stresses in components and materials.

A Research Report submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, in fulfillment of the requirements for the degree of Master of Science in Engineering(Mechanical Engineering 30 January 2017 / An extensive variety of experimental techniques exist to determining residual stresses, but few of these techniques is suitable, however, for finding the residual stresses that exist in orthotropic or anisotropic layered materials, such as carbon-fibre reinforced polymers (CFRP). Among these techniques, particularly among the relaxation techniques, the incremental hole-drilling technique (IHD) has shown to be a suitable technique to be developed for this purpose. This technique was standardized for the case of linear elastic isotropic materials, such as the metallic alloys in general. However, its reliable application to anisotropic and layered materials, such as CFRP materials, needs to be better studied. In particular, accurate calculation methods to determine the residual stresses in these materials based on the measured in-depth strain relaxation curves need to be developed. In this work, existing calculation methods and already proposed theoretical approaches to determine residual stresses in composite laminates by the incremental hole-drilling technique are reviewed. The selected residual stress calculation method is implemented using MATLAB. For these calculations, specific calibration coefficients have to be numerically determined by the finite element method, using the ANSYS software. The developed MATLAB scripts are then validated using an experimental procedure previously developed. This experimental procedure was performed using CFRP specimens, with the stacking sequence [0o, 90o]5s and, therefore, this composite laminate was selected as case study in this work. Some discrepancies between the calculated stresses using the MATLAB scripts and those imposed during the experimental calibration procedure are observed. The errors found could be explained considering the limitations inherent to the incremental hole-drilling technique and the theoretical approach followed. However, the obtained results showed that the incremental hole-drilling can be considered a promising technique for residual stress measurement in composite laminates. / MT2017

The objective of this research is to determine the thermal residual stresses and strains in bonded composite repairs on cracked metal structures. This work is an essential contribution to a fatigue damage initiation model for bonded composite repair, where knowledge of the initial stress/strain state after an elevated temperature cure is important. Furthermore, this work is an elementary part for the development of a generic certification approach to bonded composite repairs. Accounting properly for thermal residual stresses in test specimens and in real applications will assist in determining the true feasibility of a bonded composite repair. The objective of this work was realized in four stages of research. In the first stage, seven AMRL sandwich type composite bonded repair specimens were manufactured, of which one was instrumented by placing 44 strain gauges at eight planar locations and within five different interfaces. Residual strains at ambient temperature (including both thermal residual strains and other process induced strains) were measured during the manufacturing process. In the second stage, the stress free temperature for the repaired specimen was experimentally determined and the thermal residual strains measured as a function of operating temperature. In the third stage, a theoretical analysis was carried out to estimate the thermal residual stress and strain distributions in various bonded repairs. This analysis also addressed the effect of symmetrical disbonds around the crack. Finally, a finite element analysis was carried out to assess the limitations of the theoretical analysis as well as to provide a more detailed insight into the complex thermal residual stress and strain state of the AMRL sandwich type specimen. During this work it was found that high thermal residual strains (reaching 15% of the yield strain) are present in the bonded repair specimen at ambient temperature. Previous analysis schemes predicted results nearly 60% higher. The thermal residual strain versus temperature measurement showed that only very small changes in thermal residual strains occurred above 90°C leading to a defined effective stress free temperature of 85.8°C for the employed adhesive FM 73M. By utilizing an effective stress free temperature, a linear-elastic approach was used to model thermal residual stresses and strains in composite bonded repairs. Major achievements in the theoretical analysis include a linear-elastic closed form solution for tapered joints and reinforcements without the need for a numerical solution scheme, a stress field prediction ahead of the crack tip for the metal substrate of a bonded repair based on a concise complete solution of the classical fracture mechanics problem of a center crack in an infinite plate and, an extended Rose model for the prediction of the stress intensity factor of a bonded repair with symmetrical disbonds showing the severity of thermal residual stresses especially for partially disbonded composite repairs to cracked metal specimens. The key to precise predictions of thermal residual stresses in bonded composite repairs is the knowledge of the adhesive behaviour at elevated temperatures under thermal residual stress loading. A generic type specimen is presented which allows to investigate the relevant adhesive behaviour.

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The objective of this research is to determine the thermal residual stresses and strains in bonded composite repairs on cracked metal structures. This work is an essential contribution to a fatigue damage initiation model for bonded composite repair, where knowledge of the initial stress/strain state after an elevated temperature cure is important. Furthermore, this work is an elementary part for the development of a generic certification approach to bonded composite repairs. Accounting properly for thermal residual stresses in test specimens and in real applications will assist in determining the true feasibility of a bonded composite repair. The objective of this work was realized in four stages of research. In the first stage, seven AMRL sandwich type composite bonded repair specimens were manufactured, of which one was instrumented by placing 44 strain gauges at eight planar locations and within five different interfaces. Residual strains at ambient temperature (including both thermal residual strains and other process induced strains) were measured during the manufacturing process. In the second stage, the stress free temperature for the repaired specimen was experimentally determined and the thermal residual strains measured as a function of operating temperature. In the third stage, a theoretical analysis was carried out to estimate the thermal residual stress and strain distributions in various bonded repairs. This analysis also addressed the effect of symmetrical disbonds around the crack. Finally, a finite element analysis was carried out to assess the limitations of the theoretical analysis as well as to provide a more detailed insight into the complex thermal residual stress and strain state of the AMRL sandwich type specimen. During this work it was found that high thermal residual strains (reaching 15% of the yield strain) are present in the bonded repair specimen at ambient temperature. Previous analysis schemes predicted results nearly 60% higher. The thermal residual strain versus temperature measurement showed that only very small changes in thermal residual strains occurred above 90°C leading to a defined effective stress free temperature of 85.8°C for the employed adhesive FM 73M. By utilizing an effective stress free temperature, a linear-elastic approach was used to model thermal residual stresses and strains in composite bonded repairs. Major achievements in the theoretical analysis include a linear-elastic closed form solution for tapered joints and reinforcements without the need for a numerical solution scheme, a stress field prediction ahead of the crack tip for the metal substrate of a bonded repair based on a concise complete solution of the classical fracture mechanics problem of a center crack in an infinite plate and, an extended Rose model for the prediction of the stress intensity factor of a bonded repair with symmetrical disbonds showing the severity of thermal residual stresses especially for partially disbonded composite repairs to cracked metal specimens. The key to precise predictions of thermal residual stresses in bonded composite repairs is the knowledge of the adhesive behaviour at elevated temperatures under thermal residual stress loading. A generic type specimen is presented which allows to investigate the relevant adhesive behaviour. / Applied Science, Faculty of / Mechanical Engineering, Department of / Graduate

Orientador: Auteliano Antunes dos Santos Júnior / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-16T08:34:31Z (GMT). No. of bitstreams: 1 Buenos_AlexandreAparecido_M.pdf: 7987843 bytes, checksum: e9789b79f50624aea527663a778fd255 (MD5) Previous issue date: 2010 / Resumo: O processo de usinagem de materiais metálicos causa tensões residuais que podem alcançar valores significativos e influenciar na vida em serviço de componentes mecânicos. Definir o processo adequado para cada aplicação requer a previsão de quão elevada será a tensão gerada em função das variáveis do processo utilizado. Para a usinagem de chapas planas por fresamento de topo, as tensões e deformações criadas se encontram próximas à superfície, que é onde se iniciam as principais falhas de componentes mecânicos. A fim de conhecer os valores das tensões resultantes é necessário medi-las, mas os métodos destrutivos usuais são trabalhosos, requerem a reconstrução do campo de tensões a partir do alívio das tensões e nem sempre podem ser utilizados. Os métodos não destrutivos mais comuns requerem equipamentos especializados, condições controladas e quase sempre são capazes de determinar as tensões apenas na superfície. Este trabalho propõe um método alternativo para a avaliação da intensidade das tensões geradas pelo processo de usinagem, utilizando ondas longitudinais criticamente refratadas (Lcr) e a teoria acustoelástica. O trabalho consiste em avaliar o efeito da variação dos principais parâmetros de usinagem: a velocidade de corte, o avanço e a profundidade de usinagem. Foram ensaiadas amostras de aço carbono de média resistência ASTM A36, utilizado em componentes estruturais. Tais amostras foram usinadas em diversas combinações de parâmetros, o que permitiu a criação de um conjunto de relações entre os parâmetros e a tensão resultante, e que pode ser usada para a definição do melhor ajuste dos parâmetros para cada aplicação / Abstract: The process of machining of metallic materials generates residual stresses that can reach significant values and influence the service life of mechanical components. The definition of process for every application requires a forecast of how high the stress will be generated according to the process variables used. For the machining of flat sheet using face milling, the stresses and strains are created near the surface, which is where the main failures of the mechanical components start. In order to know the magnitude of stresses it is necessary to measure them, but the usual destructive methods are complex, require the reconstruction of the stress field from the relief stress and can not always be used. The nondestructive methods frequently require specialized equipment, controlled conditions and almost always are be able to determine the stresses on the surface only. This dissertation proposes an alternative method for assessing the intensity of the residual stresses generated by the machining process, using critically refracted longitudinal waves (Lcr) and the acustoelastic theory. The work is to evaluate the effect of variation of the main machining parameters: cutting speed, feed per tooth and depth of cut in machining. We tested samples of carbon steel ASTM A36 of medium strength, used in structural components. These samples were machined in various combinations of parameters, which allowed the creation of a set of relationships between the parameters and the resulting stress. These can be used to define the best fit of the parameters for each application / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica