Abstract
Based on dimensional analysis and finite element analysis (FEA), a test method was developed to determine the layer thickness of the surface residual stress using instrumented indentation testing. The relative loading curvatures of the stressed and stress-free P-h curves were obtained from the FEA results. The platform region of the curve of the relative loading curvature versus the indentation depth was used to estimate the residual stress, and the residual stress layer thickness was obtained by considering the turning point of the curve. According to the error analysis results, the proposed method is valid for estimating the residual stress layer thickness by carefully considering the material properties. The proposed method was reduced to the instrumented indentation testing method to determine the uniform residual stress when the indentation depth was far smaller than the layer thickness.
Highlights
Residual stress can form in the surface layer of parts owing to machining, heat treatment, or surface hardening.1 Surface residual stress has a significant influence on the service performance of parts; for example, it can affect fatigue life, and cause fracture or stress corrosion
The method of estimating the residual stress layer thickness using the indentation testing (IIT) was established based on dimensional analysis and finite element analysis (FEA), and error analysis was performed for validation
The residual stress was calculated using the method proposed by Lu et al.20 with the platform region of the characteristic curve (h, (C−C0)/C0)
Summary
Residual stress can form in the surface layer of parts owing to machining, heat treatment, or surface hardening. Surface residual stress has a significant influence on the service performance of parts; for example, it can affect fatigue life, and cause fracture or stress corrosion. Tsui et al. and Bolshakov et al. have found that the residual stress influences the indentation curve and contact area, whereas the average contact pressure (real hardness) is not affected by the residual stress. The value and layer thickness of the surface residual stress are concerned in the characterization of the actual parts.. Previous studies using the IIT ignored the layer thickness of the residual stress. The determination of the residual stress layer thickness is considered in the proposed model. The method of estimating the residual stress layer thickness using the IIT was established based on dimensional analysis and finite element analysis (FEA), and error analysis was performed for validation
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