Abstract
The reaming process of a 6061 aluminum alloy plate after cold expansion with a split sleeve was simulated by the finite element (FE) method based on Abaqus/CAE, and the relationship between the reaming depths and the distribution of residual stress fields was obtained by analysis. The fatigue lives of the plates under different reaming depths were calculated using the fatigue analysis software FE-SAFE and verified by fatigue tests. The results showed that reaming after expansion increased the residual compressive stress at the hole edge on the entrance surface. In addition, the fatigue life of the specimens increased with increasing reaming depth, and the best fatigue gain of the specimen was obtained when the reaming depth was 0.5 mm.
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