Abstract
The paper presents outcomes from experimental research and numerical simulations which prove the efficiency of spherical mandrelling process (SM) to enhance the fatigue life of steel structural elements with cylindrical holes. It has been proved that SM of cylindrical holes on conventional machine tools enhances the fatigue life of the respective structural element three times and more. The residual normal stress field around holes formed by SM has been determined by means of finite element analysis and the practical significance of these stresses has been proved. A finite element simulation of dynamic impact on a strip with a hole obtained by cutting only and another one formed by SM has been carried out. The comparison between the fields of stresses in both cases shows advantages of SM process on conventional machine tools as a new technology against fatigue failure.
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