Abstract
A study has been made of the residual stresses present in mild-steel rods after cold-forming by extrusion or drawing. The analysis has been conducted by means of the finite-element (FE) method using an elastic-plastic material law and the results are compared with those found using the experimental technique of neutron diffraction. Semi-quantitative agreement is found between the FE work and the practical measurement of the residual stresses. In confirmation of earlier work, the axial and circumferential residual stresses are found to be tensile at the surface and compressive near the rod axes. It is also shown that, for forming conditions otherwise the same, the residual stresses in extrusion are higher than those in drawing. This is attributed to the action of the drawing stress in causing additional plastic flow and hence reducing the residual stress that would be formed by the comparable extrusion process. In addition, the FE work shows that the stress pattern is reversed by using a very small reduction in area.
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