Modeling and Characterization of Residual Stresses in Material Processing

Abstract

Residual stresses can seriously alter (detrimentally or favorably) the mechanical behavior of materials and a component's fatigue life and crack growth behavior. They can arise from different sources and can be simulated and experimentally quantified using several different techniques. As a step in the direction of better understanding residual stresses and the different methods for its prediction, simulation, and quantification, this work reviews the different types of stresses, their physical basis, their sources, and critically presents the current most relevant approaches and limitations for residual stress modeling and experimental quantification. At the end, a brief exploratory comparison between experimental results from X-ray diffraction and hole-drilling methods using finite element (FE) models as benchmarks is conducted. Results reveal the limitations of those methods, mainly regarding plasticity effects. © 2014 Elsevier Ltd All rights reserved.