Abstract
Cold expansion is an efficient way to improve the fatigue life of an open hole. In this paper, three finite element models have been established to crack growth from an expanded hole is simulated. Expansion and its degree influence are studied using a numerical analysis. Stress intensity factors are determined and used to evaluate the fatigue life. The residual stress field is evaluated using a nonlinear analysis and superposed with the applied stress field in order to estimate fatigue crack growth. Experimental test is conducted under constant loading. The results of this investigation indicate expansion and its degree are a benefit of fatigue life and a good agreement was observed between FEM simulations and experimental results.
Highlights
The fatigue life improvement of cold expanded fasten holes is attributed to the presence of compressive residual stress induced by cold expansion
According to the experimental and numerical analysis, it can be seen that the result gave a good correlation between various methods, establishing confidence in the results of the finite element modeling for the cold expansion process
We investigated the effect of cold expansion process on the crack growth in aluminum alloy, from experimental and numerical results, we can deduce the following conclusions
Summary
The fatigue life improvement of cold expanded fasten holes is attributed to the presence of compressive residual stress induced by cold expansion. Over the last 40 years, because of its simple realization and remarkable enhancement of the fatigue life of holes (usually 3 - 5 times than that of holes without cold expansion), the cold expansion process has been widely used to improve the fatigue life of components with fastener holes [1]. (FTI, 1994), is obtained by using increased pressure to plasticize an annular zone around the hole. When the mandrel is removed and the superficial pressure on the hole is erased, a residual stress field is created due to the action of the elastic deformed material on that under plastic condition [2]
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