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    Residual Stress Case Study 01

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    murali
    Residual stresses are internal stresses that remain in a material after external forces have been removed. They are caused by manufacturing processes like welding or machining. This document discusses methods to measure and minimize residual stresses using mechanical, thermal, and evaluation techniques. Case studies are presented measuring residual stresses in titanium diaphragms, pipes, scooter frames, injector levers, and engine casings at different stages of production. X-ray diffraction and blind hole drilling methods are used to evaluate stresses before and after heat treatment or manufacturing steps.

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    Residual Stress Case Study 01

    Uploaded by

    murali
    106 views46 pages
    Residual stresses are internal stresses that remain in a material after external forces have been removed. They are caused by manufacturing processes like welding or machining. This document discusses methods to measure and minimize residual stresses using mechanical, thermal, and evaluation techniques. Case studies are presented measuring residual stresses in titanium diaphragms, pipes, scooter frames, injector levers, and engine casings at different stages of production. X-ray diffraction and blind hole drilling methods are used to evaluate stresses before and after heat treatment or manufacturing steps.

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    Residual stresses are internal stresses that remain in a material after external forces have been removed. They are caused by manufacturing processes like welding or machining. This document discusses methods to measure and minimize residual stresses using mechanical, thermal, and evaluation techniques. Case studies are presented measuring residual stresses in titanium diaphragms, pipes, scooter frames, injector levers, and engine casings at different stages of production. X-ray diffraction and blind hole drilling methods are used to evaluate stresses before and after heat treatment or manufacturing steps.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    106 views46 pages

    Residual Stress Case Study 01

    Uploaded by

    murali
    Residual stresses are internal stresses that remain in a material after external forces have been removed. They are caused by manufacturing processes like welding or machining. This document discusses methods to measure and minimize residual stresses using mechanical, thermal, and evaluation techniques. Case studies are presented measuring residual stresses in titanium diaphragms, pipes, scooter frames, injector levers, and engine casings at different stages of production. X-ray diffraction and blind hole drilling methods are used to evaluate stresses before and after heat treatment or manufacturing steps.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 46

    Residual Stresses are :

    (i) Internal Stresses remaining


    after removing all external load

    (ii) Caused due to various


    operations performed on the
    material

    (iii) Self Equilibrating


    Methods to minimize Residual
    Stresses

    Mechanical Methods :

    * Vibration Stress Relieving


    * Over Stressing
    * Hammer Peening
    * Needle Pin Peening
    Methods to minimize Residual
    Stresses

    Thermal Methods :

    * Stress Relief Annealing


    * Post Heating
    * Local Stress Relieving
    * Spot Heating
    Evaluation of Residual Stresses

    • Prevent Pre-mature failures

    • Optimize the component Design

    • Improve the performance of the component

    • Minimize fabrication related problems


    Methods of Evaluation of
    Residual Stresses :

    (a) X-Ray Diffraction Method


    (Non-Destructive)

    (b) Blind Hole Drilling Method


    (Semi-Destructive)
    Limitations of X-Ray
    Diffraction Technique

    • Presence of course grains

    • Rough surface finish of the


    component
    Case Study I

    Residual Stress Measurement


    in Titanium Diaphragm

    X-Ray Diffraction
    Technique
    Objective
    To study the effectiveness of the
    Heat Treatment on Titanium
    Diaphragm, manufactured in different
    stages :

    - Raw Material
    - Root Welded
    - Rim Welded
    Root Welded Diaphragm

    Root Welded Diaphragm


    Experimental Plan
    • Residual Stress Measurement on
    raw material, machined, root
    welded and rim welded diaphragms

    • Carrying-out Heat Treatment of the


    rim welded diaphragm

    • Residual Stress Measurement of


    the rim welded diaphragm after
    Heat Treatment
    Heat Treatment Parameters
    • Furnace Used : 1 T Electric Furnace

    • Heating Rate : 100oC

    • Soaking Temp : 750oC

    • Soaking Time : Two Hours

    • Cooling Rate : 100oC

    • Environment : Argon

    • A Special SS chamber was used for HT


    Results
    • Yield Strength of the material : 900 MPa

    • Stress in the raw material : -320 MPa

    • Stress after completion of welding: -38 MPa

    • Stress after HT : 44 MPa


    Case Study II

    Residual Stress Measurement


    on P91 pipe.

    X-Ray Diffraction
    Technique
    Objective

    To study the effectiveness of the


    local stress relieving heat treatment
    by resistance heating method of P91
    pipes.
    Experimental Plan
    • Evaluation of Residual Stress
    of the pipe before heat treatment

    • Carrying - out local stress


    relieving heat treatment of the
    pipe using resistance heating
    elements

    • Evaluation of Residual Stress of


    the pipe after heat treatment
    Results

    Magnitude of stress

    before heat treatment : -234 MPa

    after heat treatment :-73 MPa


    Case Study III

    Residual stress
    measurement
    on
    Scooty frame
    Objective

    Comparison of of residual stress in Manual


    welded and Robotic welded Frames

    Comparison of Penetration levels in both the


    frames
    Observations - Residual Stress
    Manual Frame :
    Tensile and Compressive residual stresses
    observed with non uniform magnitude
    Magnitude varies from +183 to -331 MPa

    Robotic welded Frame:


    One location Tensile Residual stress. In
    other locations Compressive stresses
    noticed
    Uniform Magnitude of compressive stress
    observed
    Observations - Penetration level

    Manual Frame :
    16%, 46%, 22%, 22% and 9%

    Robotic welded Frame:


    20%, 20%, 50%, 5% ** and 15%
    ** Mis-alignment noticed
    Case Study IV

    RESIDUAL STRESS
    MEASUREMENT
    ON
    INJECTOR LEVERS
    OBJECTIVE

    To Measure Residual Stress in the


    Injector Levers used in Automobiles
    in the “Shot-Peened” condition
    XRD STRESS ANALYSER
    RESULTS

    Condition O Degree 45 Degree 90 Degree

    Thumble Blasting -535.1 MPa -525.1 MPa -507.4 MPa


    Spinner Hanger -430.0 MPa -450.2 MPa -452.3 MPa
    Imported -348.2 MPa -360.0 MPa -394.1 MPa
    Local -468.5 MPa -468.3 MPa -----
    INFERENCE

    Nearly uniform magnitude of residual stress


    observed
    High magnitude of residual stress noticed
    which could be due to shot peening
    The indigenously made lever shows higher
    compressive stress than imported lever
    Residual Stress Measurement

    Method Blind Hole Drilling


    Standard ASTM E 837
    Strain Gauge Rosette Type ( 3mm)
    Drilling Guide RS - 200 Milling Guide
    Drill Size Dia 1.6 mm
    Strain Meter Digital Type (UPM 100)
    Limitations of Blind Hole
    Drilling Method

    • Presence of stress gradients along


    the depth
    • Deformation of hole during drilling
    • Errors associated with drilling
    Case Study V

    Residual Stress Measurement


    on Electro-gas welded plates

    Blind Hole
    Drilling Method
    Objective

    To evaluate the levels of residual


    stresses before and after heat
    treatment in Electro-Gas Welded
    Plates welded with different
    parameters
    Experimental Plan
    • Evaluation of Residual Stress of
    both the plates before heat
    treatment

    • Carrying - out furnace stress


    relieving heat treatment of the
    plates

    • Evaluation of Residual Stress of


    the plates after heat treatment
    Welding Parameters

    Parameters Plate 1 Plate 2


    Thickness 20 mm 20 mm
    Wire 1.6 mm 1.6 mm
    Shielding Gas CO2 CO2
    Gap 15 mm 17 mm
    Current 360 A 350 A
    Voltage 36 V 33 V
    Speed 50 mm / Min. 48.7 mm/Min.
    Flow Rate 20 Lit/Min 20 Lit/Min
    Results (Plate 1)
    Condition Weld HAZ Base
    metal

    As welded 15 10 -2.3

    After stress 4.6 -0.4 3.9


    relieving
    Results (Plate 2)
    Condition Weld HAZ Base
    metal

    As welded 32 11 -4

    After stress 13 3.4 7.8


    relieving
    Case Study VI

    RESIDUAL STRESS
    MEASUREMENT ON ENGINE
    CASING IN DIFFERRENT
    STAGES OF MANUFACTURE
    OBJECTIVE

    To measure residual stress in


    engine casing in different stages
    of manufacture and compare
    with the imported casing
    RESULTS
    Condition Max. Stress Min Stress
    (Kg/sq.mm) (Kg/sq.mm)

    As Cast 3.72 -2.57


    As Machined 1.74 -3.1
    As Bush Pressed 1.16 -5.90
    As Serviced 8.04 -4.0
    Imported -1.78 -5.45
    INFERENCE

    As compared to yield strength of the material,


    the stresses were between 12% to 24%

    Unless there is a defect, this stress level could


    not induce any failure

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