Three Dimensional Finite Element Analysis of a Split-Sleeve Cold Expansion Process
Source abstract
Abstract
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.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Fatigue and fracture mechanics · Surface Treatment and Residual Stress · High-Velocity Impact and Material Behavior
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Mechanical Engineering, Mississippi State University, Starkville, MS 39762
Department of Aerospace Engineering, Mississippi State University, Starkville, MS 39762
Department of Mechanical and Aeronautical Engineering, University of California, Davis, CA 95616
Structural Methods and Prognostics, Sikorsky Aircraft Corp., Stratford, CT 06497
References (22)
Show source-provided references
1. Restis, J., and Reid, L., 2002, “Process Specification 8101D: Cold Expansion of Holes Using the Standard Split Sleeve System and Countersink Cold Expansion,” Fatigue Technology, Seattle, WA.
2. Rich, D. L., and Impellizzeri, L. F., 1977, “Fatigue Analysis of Cold-Worked and Interference Fit Fastener Holes. Cyclic Stress-Strain and Plastic Deformation Aspects of Fatigue Crack Growth,” American Society for Testing Materials Paper No. ASTM STP 637.10.1520/STP27993S ↗
3. Elastic-Plastic Stress Analysis of Cold Expanded Fastener Holes10.1111/j.1460-2695.1995.tb00141.x ↗
4. Fastran Analyses of Coupons With Residual Stresses Due to Overloads and Cold-Worked Holes
5. A Finite Element Simulation of the Cold Working Process for Fastener Holes10.1243/0309324971513418 ↗
6. An Assessment of Residual Stress Measurements Around Cold-Worked Holes10.1007/BF02317546 ↗
7. Three-Dimensional Finite Element Analysis of the Cold Expansion of Fastener Holes in Two Aluminum Alloys10.1115/1.1448922 ↗
8. Finite Element Analysis of the Residual Stress by Cold Expansion Method Under the Influence of Adjacent Holes10.1016/j.jmatprotec.2004.04.271 ↗
9. Creep Relaxation of Residual Stresses Around Cold Expanded Holes10.1115/1.1310305 ↗
10. Three-Dimensional Finite Element Analysis of Cold Expansion of Adjacent Holes10.1016/S0020-7403(98)00007-1 ↗
11. The Effect of Cold Expansion on Improving the Fatigue Life of Fastener Holes10.1016/S1350-6307(02)00028-6 ↗
12. A Novel Method of Cold Expansion Which Creates Near-Uniform Compressive Tangential Residual Stress Around a Fastener Hole10.1111/j.1460-2695.2004.00727.x ↗
13. Numerical Simulation of Cold Working of Rivet Holes10.1016/j.finel.2005.01.001 ↗
14. Residual Stress Effect on Fatigue Striation Spacing in a Cold-Worked Rivet Hole10.1016/j.tafmec.2004.08.003 ↗
15. Effect of Residual Stress Around Cold Worked Holes on Fracture Under Superimposed Mechanical Load10.1016/S0013-7944(99)00050-8 ↗
16. Private Conversation
17. Numerical and Experimental Study of Cold Expansion Process in 7085 Plate Using a Modified Split Sleeve10.1016/j.jmatprotec.2007.01.008 ↗
18. Rice, R. C., Jackson, J. L., Bakuckas, J., and Thompson, S., 2003, “Metallic Materials Properties Development and Standardization,” Metallic Materials Properties Development and Standardization, Report No. MMPDS-01 DOT/FAA.
19. ANSYS Inc., 2001, ANSYS Release 11.0 Documentation, Chap. 8, pp. 3–12.
20. Cross-Sectional Mapping of Residual Stresses by Measuring the Surface Contour After a Cut10.1115/1.1345526 ↗
21. Assessment of Tensile Residual Stress Mitigation in Alloy 22 Welds Due to Laser Peening10.1115/1.1789957 ↗
22. Laser Surface-Contouring and Spline Data-Smoothing for Residual-Stress Measurement10.1007/BF02428177 ↗