Experimental and computational modeling of bulk residual stress for aeronautical components with distinct geometries

Abstract

To predict and minimize machining distortion in the manufacturing process, bulk residual stresses in aeronautical components with distinct geometries were investigated via experimental mechanics and numerical simulation. The residual stress state was appropriately simplified according to geometric/processing feathers and deformation patterns of the investigated parts. In each case study, an optimal experimental method was selected to reconstruct the concerned stress tensor. Thereafter, qualitative comparison and validation were performed using cross-method verification and/or numerical simulation. Additionally, the spatial resolution and distribution characteristics of the residual stress were analyzed and discussed in detail. The results revealed that thermal and mechanical nonuniformity caused by material processing is the main source of bulk residual stress in the investigated components. Furthermore, the effectiveness of the contour method on the measurement of different geometric components was verified by numerical simulation. Combining the accurate measurement of the characteristic plane and the appropriate numerical simulation of the global stress field, an engineering-oriented approach for full-field stress evaluation was proposed. This research can provide valuable engineering guidance and suggestions for stress evaluation and distortion analysis prior to manufacturing of integral structures.