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Three Dimensional Finite Element Analysis of a Split-Sleeve Cold Expansion Process

J. Eng. Mater. Technol.  -- July 2009 --  Volume 131,  Issue 3, 031007 (8 pages)
doi:10.1115/1.3120392

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Author(s):
S. Ismonov and S. R. Daniewicz
Department of Mechanical Engineering, Mississippi State University, Starkville, MS 39762

J. C. Newman, Jr.
Department of Aerospace Engineering, Mississippi State University, Starkville, MS 39762

M. R. Hill
Department of Mechanical and Aeronautical Engineering, University of California, Davis, CA 95616

M. R. Urban
Structural Methods and Prognostics, Sikorsky Aircraft Corp., Stratford, CT 06497
A cold expansion process is used to prolong the fatigue life of a structure under cyclic loadings. The process produces a beneficial compressive residual stress zone in the hole vicinity, which retards the initiation and propagation of the crack at the hole edge. In this study, a three-dimensional finite element model of the split-sleeve cold expansion process was developed to predict the resulting residual stress field. A thin rectangular aluminum sheet with a centrally located hole was considered. A rigid mandrel and an elastic steel split sleeve were explicitly modeled with the appropriate contact elements at the interfaces between the mandrel, the sleeve, and the hole. Geometrical and material nonlinearities were included. The simulation results were compared with experimental measurements of the residual stress. The influence of friction and the prescribed boundary conditions for the sheet were studied. Differences between the split-sleeve- and the non-split-sleeve model solutions are discussed.

©2009 American Society of Mechanical Engineers

History: Received 19 September 2008; revised 20 February 2009; published 26 May 2009
doi: http://dx.doi.org/10.1115/1.3120392

KEYWORDS and PACS

Keywords
PACS
  • 81.40.Np
    Fatigue, embrittlement, fracture and failure
  • 62.20.me
    Fatigue in solids
  • 62.20.mt
    Cracks in solids
  • 65.40.De
    Thermal expansion; thermomechanical effects (crystalline solids)
  • YEAR: 2009

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PUBLICATION DATA

Coden:
JEMTA8
ISSN:
0094-4289 (print)   1528-8889 (online)
Publisher:
AIP is a member of CrossRef ASME

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