The mechanics of prestress and elastic recovery resulting from dimple formation in steel sheets: Comprehensive numerical and experimental studies

Abstract

Residual stress is rarely considered as an initial condition for Finite Element Analysis (FEA), or used in the component design. A comprehensive numerical and experimental investigation into prestressed steel sheets is conducted. Residual stresses at specific locations were introduced into the steel sheets by dimple formation. FEA is used to simulate dynamic dimple forming of a mild steel disk due to a tool impact and detect the existence of prestress after dimple formation. A physical drop-hammer was used to form a range of dimple sizes in disks to experimentally validate the FEA predictions associated with dimple depth. Dimples were then created using a screw press and the prestress was measured by strain gauges beyond the zone of permanent out-of-plane deformation associated with a dimple. The experimental strain gauge measurements during dimple formation were found to be consistent with FEA predictions. The results demonstrated that the predicted and measured radial and tangentially projected stress components remain in steel sheets after forming a dimple. Furthermore, the predicted prestress was greater near to the dimple formation and occurred at higher magnitudes in the tangential direction than the radial direction. The highest prestress remaining in the disk was at the magnitude of the material’s ultimate tensile stress, predicted in the tangential direction at the edge of the dimple. The numerical and experimental results showed the three stages of prestress formation: the development of stresses during dimple formation, the elastic recovery after the dimple forming, and the final prestressed equilibrium state of the rimmed disk.