Stress Analysis Research Articles

New high sensitivity approach for a quantitative visualization of the continuous whole-field stress evolution in digital photoelasticity

Digital photoelasticity is a widely used technique for experimental stress analysis on mechanical models subjected to loading conditions, due to its ability to reveal the stress information through color fringe patterns and consequently demodulate it computationally to achieve a quantitative evaluation. In this process, some limitations persist, such as, expertise dependence, experimental repeatability, sensitivity to load increments, and weak performance under experimental conditions, especially in time-dependent scenarios. In response to these weaknesses, the method “Quantitative Visualization of the Continuous Whole-Field Stress Evolution” introduced the ability to perform a complete demodulation of the fringe patterns generated in time-dependent applications, achieving high performance compared to conventional photoelasticity methods. This paper proposes a new highly sensitive approach for a quantitative visualization of the continuous whole-field stress evolution in digital photoelasticity by incorporating an inverse signal process and a multi-stage strategy. The algorithm aims to ensure the performance under high fringe order conditions while exhibiting high sensitivity in cases where the maximum stress obtained is less than one fringe order. The results presented validate its effectiveness in demodulating full-field stress distributions, especially in scenarios where the loading condition induces fringe orders less than one, thus contributing to the broader applicability of digital photoelasticity.

Assessment of Metaverse wearable technologies for smart livestock farming through a neuro quantum spherical fuzzy decision-making model

Livestock wearable technologies are innovations designed to ensure livestock health management. However, the user aspect of these devices from farmers’ perspective is still questionable. Additionally, livestock wearables are still in progress compared to the other wearables. Thus, this research aims to identify key design features regarding wearable smart collars (WSCs) and rank the alternative WSC prototypes within Metaverse, allowing farmers to select the best wearable device. To this end, an integrated neuro quantum spherical fuzzy multi-criteria decision-making (MCDM) framework is introduced via facial expressions to obtain the priority weights of WSC criteria with the improved decision-making trial and evaluation laboratory (DEMATEL) approach and to rank the WSC alternatives in Metaverse through the improved multi-objective optimization based on ratio analysis (MOORA) model. The novelties of this research are: (1) to build and introduce a novel decision support tool based on facial expressions, expert recommendations, and the quantum spherical fuzzy sets, (2) to guide industrial designers about the essential features of WSCs, whereas they are designing these devices, and (3) to help smallholder farmers to decide on the best WSC to enhance animal welfare and efficiency of animal production. Concerning the findings, “sound and stress analyzer” is the most significant feature, followed by “disease detection” and “price.” Moreover, Prototype 3 is the best WSC for farmers to adopt for livestock health management. Some essential implications are further presented.

Evaluation of stress distributions in endodontically treated anterior incisors under occlusal and trauma-induced forces following various restoration treatments: A finite element analysis.

The aim of this study was to calculate the stress distribution of fiberglass post associated with resin composite crown restoration and fiberglass posts with zirconia restorations in mature and immature endodontically treated central maxillary incisor under various loading conditions. The study created six different study models in a virtual environment: healthy mature maxillary central teeth, intact immature maxillary central teeth, mature maxillary central teeth with fiberglass post associated with resin composite crown restoration, immature maxillary central teeth with fiberglass post associated with resin composite crown restoration, mature maxillary central teeth with fiberglass posts and zirconia restoration, and immature maxillary central teeth with fiberglass posts and zirconia restoration. Loading conditions simulating mastication, trauma, and bruxism were applied to each of the models at different angles and amounts. The von Mises and the maximum and minimum principal stress values in tooth structures (dentin) and support structures (bone, PDL) and materials were observed using finite element stress analysis. The highest stress values in the tissue and the restoration structure were observed for masticating force and crowns rehabilitated with zirconia restorations. None of the compared loading conditions and restorations showed destructive stress values on periodontal ligament or bone. The mature and immature endodontically treated central maxillary incisors can be better rehabilitated using fiberglass post associated with resin composite crown restoration and may be preferred to zirconia restorations in order to reduce the stresses on the surrounding tissues and teeth. However, further clinical studies are needed to fully explore this topic.

Evaluation of the teratogenic potency of bulk zinc oxide and its nanoparticles on embryos of the freshwater snail, Helisoma duryi

Bulk zinc oxide (ZnO-BPs) and its nanoparticles (ZnO-NPs) are frequently used in various products for humans. Helisoma duryi embryos can serve as effective model organisms for studying the toxicity of NPs. This study aimed to compare the teratogenic potency of ZnO-BPs and ZnO NPs in the embryonic stages of H. duryi to evaluate the utility of this snail as a bioindicator for ZnO-NPs in the aquatic environment. The mechanisms of teratogenesis were evaluated by determination of the LC50, studying the effect of sub-lethal concentrations of both ZnO forms on the embryos, and studying their enzyme activity, oxidative stress, and biochemical analysis. The SDS-PAGE electrophoresis was undertaken to assess the effect of ZnO-BPs and ZnO NPs on protein synthesis. The results revealed that the veliger stage of H. duryi is the specific stage for bulk and nano ZnO. ZnO-NPs proved to be more toxic to snails’ embryos than ZnO-BPs. Exposure to ZnO influences specific types of defects in development, which in the case of BPs are far less drastic than those caused by NPs. Thus, the toxicity of ZnO-NPs in embryonic development is due to their unique physicochemical properties. The observed malformations include mainly hydropic malformation, exogastrulation, monophthalmia, shell misshapen, and cell lyses. Almost all tested oxidative biomarkers significantly changed, revealing that ZnONPs display more oxidative stress than ZnO-BPs. Also, the low concentration of ZnO induces many disturbances in the organic substances of veliger larvae, such as a decrease in the total protein and total lipid levels and an increase in the glycogen level. The results indicated that ZnO-BPs increase the number of protein bands. Conversely, ZnO-NPs concealed one band from treated egg masses, which was found in the control group. Embryos of snail are an appropriate model to control freshwater snails. This study demonstrates that H. duryi embryos can serve as effective model organisms to study the toxicity of ZnO-NPs.

Residual Stress and Texture Analysis of Leaf Spring Failure

Residual Stress and Texture Analysis of Leaf Spring Failure

REVIEW: AN EXPERIMENTAL STUDY ON EFFECT OF NANO MATERIALS ON STRENGTH OF CONCRETE AND PLANE STRESS ANALYSIS USING ANSYS SOFTWARE

These days, making efficient and cost-effective use of resources has taken precedence. The main ingredient in concrete, cement has been under criticism in recent years for the quantity of CO2 released during production. Although cement has better mechanical properties, it hasn't been able to live up to the expectations in terms of durability. Owing to cement's shortcomings, scientists started looking into additives that would enhance concrete's qualities while also making it stronger and lighter. Fly ash, silica fume, and other micro particles were added to cementitious materials to improve their compactness, strength, and durability. These additives were also selected because they are eco-friendly by products of industrial waste that may be handled ethically. Fly ash has significant disadvantages because it is not good for initial strength increase and setting time. Because silica fume affects cementitious material performance, researchers have recently become interested in combining it with ceramic waste and rice husk ash. A more effective way to utilize rice husk ash, a by-product of rice cultivation, would be to replace 10% to 15% of cement. Studies have shown improvements in the durability performance of recycled ceramic waste concrete and rice husk ash concrete. There are issues since the RHA production process is quite time-consuming. With the discovery of nano-particles (NP) smaller than 100 nm, researchers have advanced the field of nanotechnology to new levels. The mechanical properties of many materials, including polymers and cementitious materials, can be enhanced by NP. NP is also helpful in the fields of food, engineering, and medicine. This led researchers to investigate the effects of nano-silica (NS) on concrete in further detail. Nano materials can improve the compressive strength and ductility of concrete. In this project an effort will be made to increase the compressive strength of concrete using Nano materials and waste product like GGBS. Also plane stress analysis of concrete cubes and cylinders is to be done using Ansys Software to find deformation, principal stresses and shear stresses. Keywords: Nano –Silica, Nano Titanium dioxide, Ansys, GGBS, Compressive strength

An investigation of stress analysis via finite element methods on compacted snow runways

Compacted snow runways for heavy wheeled aircraft are challenging in polar regions and possible extraterrestrial infrastructure constructions. A finite element method was successfully employed to simulate a wheel landing on layered snow using the ABAQUS software package based on the Phoenix runway in Antarctica. First, the method was validated with theoretical results of several layered systems. Thereafter, basic parameters of snow were chosen with reference to the Phoenix runway's pavement. Stress distributions under landing gear were calculated for the C17, A319, B757 and Il-76 aircraft. Furthermore, the effect of subgrades on stress distributions were discussed. This study explores current knowledge on snow pavements and provides technical support for the design and construction of compacted snow runways.

Interface Stress Analysis and Failure Mechanism of Rock–Concrete Composite Structures Under Multi-directional Stress Waves

Interface Stress Analysis and Failure Mechanism of Rock–Concrete Composite Structures Under Multi-directional Stress Waves

The relation between mental health and career-related stress among prospective graduates in higher education stage during the COVID-19 pandemic: an evidence based on network analysis.

The outbreak of the COVID-19 pandemic has disrupted people's routine, bringing uncertainty and stress, leading to mental health issues. This situation is particularly acute among Chinese prospective graduates in higher education stage as they cannot predict the outcomes of their studies, graduation, and career development, and therefore experience career-related stress. This study included 4041 prospective graduates in higher education stage (using handy sampling) recruited in March 2020 as participants (M Age = 22.56, SD = 1.865), utilizing a Sparse Gaussian Graphical Model for regularized partial correlation network analysis of depression symptoms (by PHQ-9), anxiety symptoms (by GAD-7), and career-related stress, which aims to explore the role of career-related stress in the symptom networks of depression and anxiety among prospective graduates in their final semester. The results revealed that fatigue, sad mood, and psychomotor symptoms in depression, as well as uncontrollable worry and trouble relaxing in anxiety, were central symptoms in the network. Additionally, sad mood and guilt belonging to depressive symptoms, and feeling afraid, restlessness, and irritability belonging to anxiety symptoms, served as bridge symptoms connecting symptom communities. Specifically, guilt as a depressive symptom showed a strong association with employment stress in career-related stress. There were no significant differences in network structure and global strength based on participants' gender. However, despite no significant differences in network structure, the global strength of prospective graduates from Wuhan was significantly lower than samples from non-Hubei provinces, possibly indicative of a Typhoon Eye Effect. The findings of this study can inspire psychological professionals in higher education institutions to provide support for mental interventions and therapies for prospective graduates, and addressing career development issues.

Research on the strain gauge mounting scheme of track wheel force measurement system based on high-speed wheel/rail relationship test rig

PurposeThis paper aims to analyze the stress and strain distribution on the track wheel web surface and study the optimal strain gauge location for force measurement system of the track wheel.Design/methodology/approachFinite element method was employed to analyze the stress and strain distribution on the track wheel web surface under varying wheel-rail forces. Locations with minimal coupling interference between vertical and lateral forces were identified as suitable for strain gauge installation.FindingsThe results show that due to the track wheel web’s unique curved shape and wheel-rail force loading mechanism, both tensile and compressive states exit on the surface of the web. When vertical force is applied, Mises stress and strain are relatively high near the inner radius of 710 mm and the outer radius of 1110 mm of the web. Under lateral force, high Mises stress and strain are observed near the radius of 670 mm on the inner and outer sides of the web. As the wheel-rail force application point shifts laterally toward the outer side, the Mises stress and strain near the inner radius of 710 mm of the web gradually decrease under vertical force while gradually increasing near the outer radius of 1110 mm of the web. Under lateral force, the Mises stress and strain on the surface of the web remain relatively unchanged regardless of the wheel-rail force application point. Based on the analysis of stress and strain on the surface of the web under different wheel-rail forces, the inner radius of 870 mm is recommended as the optimal mounting location of strain gauges for measuring vertical force, while the inner radius of 1143 mm is suitable for measuring lateral force.Originality/valueThe research findings provide valuable insights for determining optimal strain gauge locations and designing an effective track wheel force measurement system.

Settlement and stress analysis in stabilized slab- and pile-supported embankment based on double-equal settlement plane

PurposeThe soft stabilized slab and pile-supported (SSPS) embankment is an improvement technique to increase the efficiency of resources in road construction. To capture the effects of stabilized slabs on the stress transfer mechanism, the differential settlements and the lateral displacement of the embankment completely. A theoretical model of SSPS is proposed by considering the effect of soil arching and the interaction between the embankment fill, stabilized soil, pile, foundation soil and bearing stratum.Design/methodology/approachIn the theoretical model, the stress and strain coordination relationship of the system was analyzed in view of the minimum potential energy theory and equal settlement plane theory. Subsequently, the theoretical method was applied to field tests for comparison. Finally, the influence of the elastic modulus and the thickness of the stabilized slab on the stress concentration ratio and foundation settlement were examined.FindingsIn addition to the experimental findings, the method has been revealed to be reasonable and feasible, considering its ability to effectively exploit the stabilized slab effect and improve the bearing capacity of soil and piles. An economical and reasonable arrangement scheme for the thickness and strength of stabilized slabs was obtained. The results reveal that the optimum elastic modulus was chosen as 28 MPa–60 MPa, and the optimum thickness of the stabilized slab was selected as 1.5 m–2.1 m using the parameters of field tests, which can provide guidance to engineering design.Originality/valueAn optimization calculation method is established to analyze the load transfer mechanics of the SSPS embankment based on a double-equal settlement plane. The model’s rationality was analyzed by comparing the settlement and stress concentration ratios in the field tests. Subsequently, the influence of the elastic modulus and the thickness of the stabilized slab on the stress concentration ratio and settlement were examined. An economical and reasonable arrangement scheme for the thickness and elastic modulus of stabilized slabs was obtained, which can provide a novel approach for engineering design.

Failure analysis and preventative measures on cracking of tube-to-tubesheet joints of the large-scale heat exchanger

A large-scale heat exchanger in an EO/EG plant suffered a severe leakage failure after 3 years of service, and numerous fractures and cracks were found in the tube-to-tubesheet joints. A series of failure investigations, including macroscopic and microscopic inspection, physicochemical analysis, metallographic examination, and stress analysis, have been used to clarify the causes of cracking of tube-to-tubesheet joints. The macroscopic inspection revealed that the cracking of the joints occurred on the tube inlet side, and the fracture exhibited circumferential cracking. Scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) presented that the fracture is a mixture of transgranular and intergranular cracking (predominantly intergranular), and the surface of the fracture is covered by corrosion products with chlorine, oxygen, and copper content. Furthermore, the stress analysis concluded that the joints were subjected to residual stresses, tensile stresses, and thermal stresses. Therefore, the cracking of the tube-to-tubesheet joints was caused by stress corrosion cracking (SCC), which originated from crevice corrosion and intergranular corrosion. Then, the corrosion mechanism involved in this failure was discussed in detail, and corresponding preventive measures were proposed. Achievements in this paper may supplement the failure database of tube-to-tubesheet joints in large-scale heat exchangers and reduce similar failures through engineering practices.

Optimizing Structural Steel Spur Gear Design for Reduced Stress Concentrations in Industry 4.0 Using Finite Element Analysis

Abstract: The advent of Industry 4.0 has highlighted the importance of spur gears in power transmission across the automotive, aerospace, and marine industries. However, these gears are susceptible to failure due to bending and contact stresses from fatigue. Designing an involute gear profile presents challenges, particularly in managing tooth root stresses and avoiding interference. This study tackles these issues through comprehensive stress analysis, using modeling and FEM assessment. The focus is on evaluating bending stresses at critical locations and identifying strategies to reduce stress concentrations at the gear tooth root. By enhancing gear robustness, this research could contribute to potential patents in gear technology. Background: Spur gears are crucial for power transmission but often fail due to fatigue-induced stresses and design challenges at the tooth root. Objective: This study aims to address spur gear design challenges through comprehensive stress analysis, using modeling and FEM to assess bending stresses and explore strategies to reduce stress concentrations at the tooth root. Methods: The research uses SolidWorks and ANSYS for FEM analysis, focusing on bending stresses and exploring modifications in gear design using various materials for optimization. Results: The analysis shows strategic modifications to the gear's fillet radius and addendum can reduce stress at the tooth root by 38.26%, with stainless steel being the optimal material for enhanced gear strength. Conclusion: The study emphasizes strategic adjustments in fillet radius and addendum to reduce stress in spur gears, highlighting stainless steel's superior performance for optimized design and enhanced strength.

Mitigation of Volumetric Expansion in Silicon Anodes via Engineered Porosity: Electrochemical Performances and Stress Distribution Implication

To overcome the significant volume expansion issue encountered by traditional silicon anodes in lithium‐ion batteries, this study employs chemical etching techniques to treat aluminum–silicon alloys of various ratios, successfully preparing three types of porous silicon electrode materials with different pore structures. Through a series of electrochemical tests, this article investigates the role of porous silicon structures in improving electrode performance. The results demonstrate that the porous silicon anodes exhibit superior cycle stability and rate capability compared to traditional solid silicon anodes. This confirms the effectiveness of the porous structure in mitigating the significant volume expansion during the charge and discharge process of silicon materials and in preventing premature electrode failure, thereby significantly enhancing the electrode's cycle life. Remarkably, the porous silicon with a high porosity rate shows exceptionally outstanding performance. Additionally, using computer simulations, this study also models the impact of changes in pore size within the porous silicon material at different states of charge and discharge on the stress distribution at the particle center and surface. These experimental and simulation results jointly provide strong empirical evidence for applying porous silicon materials as high‐performance anode materials for lithium‐ion batteries and offer essential guidance for future stress analysis and electrode design of porous silicon electrode materials.

Probing High-order Protein Complexes Using Native Mass Spectrometry and Hydrogen/Deuterium Exchange Mass Spectrometry: A Case Study Using Fresh and Commercial Hemoglobin Samples.

Native mass spectrometry (MS) analysis of protein complexes is highly susceptible to matrix effect, and addressing this predicament using buffer exchange is a common approach. Nevertheless, optimization of the buffer exchange protocol is not trivial. With the use of hemoglobin (Hb) as the model entity, it was discovered that the native mass spectrum of protein assembly is highly dependent on the buffer-exchange protocol. Given the dependence of native MS on the purification protocol, this work attempts to use hydrogen/deuterium exchange mass spectrometry (HDX-MS) for comparative studies of hemoglobin complexes in untreated fresh and commercial samples. The information obtained from the HDX study was found to correlate well with the native mass spectrometry analysis of the properly buffer-exchanged Hb samples. Both native MS and HDX-MS showed that the fresh Hb sample has retained the expected tetrameric structure, whereas the commercial Hb has largely been denatured to the dimeric form. These findings prove the complementarity of native MS and HDX-MS in the analysis of high-order protein complexes and stress the necessity to validate the integrity of the high-order structures of the proteins prior to the use of the protein samples for other biomedical studies.

Torque moments and stress analysis in two passive self-ligating brackets across different incisor inclinations: A 3-dimensional finite element study

ObjectiveTo compare torque expression characteristics between rectangular slot (0.022″ x 0.028″) Damon Q passive self-ligating brackets (Ormco, Glendora, Calif) and square slot (0.021″ x 0.021″) Pitts 21 brackets (OC Orthodontics) using 0.019″ x 0.025″ Stainless Steel and 0.020″ x 0.020” Titanium Molybdenum alloy wires at various incisal inclinations using finite element analysis. The null hypothesis was that there were no differences in torque expression in both tested groups. MethodsReporting guidelines for in-silico studies using finite element analysis in medicine (RIFEM) were used. Damon Q and Pitts 21 brackets were scanned and 3D models generated. Brackets were placed on a 3-D model of a maxillary central incisor with its long axis inclined at 0⁰,5⁰,10⁰,15⁰ and 20⁰ to the occlusal plane. Final 0.019″ x 0.025″ SS and 0.020″ x 0.020” TMA archwires were inserted into slots of both tested brackets. Geometric models were converted into finite element models. Material properties were assigned for involved structures with automatic meshing performed by software. Torque movements were simulated with the FE program Ansys Space claim R 22. ResultsTorque moment values, torque expression and Von - Mises stress was higher in Pitts 21 than Damon Q at all inclination angles. There was a gradual increase in the magnitude of values with decrease in incisal inclination. ConclusionSquare slot passive self-ligating brackets show superior torque expression characteristics as compared to rectangular wire-rectangular slot combinations. The FEM results should be validated with in-vivo studies in order to confirm the findings.

Analysis and verification of electrodynamic force, thermal stress and current sharing for CRAFT converter structure design

In the design realm of fusion power supplies, structural components play a pivotal role in ensuring the safety of fusion devices. To verify the reliability of the converter structure design at the Comprehensive Research Facility for Fusion Technology (CRAFT), meticulous analysis of the converter's dynamic impact is carefully performed based on the worst fault current (400 kA), firstly. Subsequently, the thermal stress analysis based on the maximum allowable steady-state temperature is finished, and the equivalent thermal stress, thermal deformation, maximum shear stress of a single bridge arm and the whole converter are studied. Furthermore, a simple research method involving the current-sharing characteristics of a bridge arm with multi-thyristor parallel connection is proposed using a combination of Simplorer with Q3D in ANSYS. The results show that the current-sharing characteristics are excellent. Finally, the structural design has been meticulously tailored to meet the established requirements.

Research on the Analysis of Residual Stress in Heat Treatment of Bellows Using ABAQUS.

Taking austenitic stainless-steel bellows as the research object, a finite element model for the heat treatment of austenitic stainless-steel bellows was constructed based on ABAQUS CAE 2022. The physical properties of the bellows after the heat treatment were analyzed using experimental and simulated curve processing analysis methods. The changes in residual stress and deformation in relation to the bellows under different cooling times were explored, as well as the distribution of residual stress and deformation at a certain cooling time. The results show that as the cooling time of the heat treatment increases, the residual stress of the bellow decreases significantly, the reduction rate accelerates, and the degree of deformation gradually decreases. When the cooling time of the heat treatment is 900 s, the residual stress of the wave peak in the middle position of the bellow is relatively small, and the residual stress value of the wave valley along the axis direction does not change significantly. The deformation degree of the wave peak and valley axis direction is relatively uniform.

Aeronautical composite/metal bolted joint and its mechanical properties: a review

PurposeBolted joint is the most important connection method in aircraft composite/metal stacked connections due to its large load transfer capacity and high manufacturing reliability. Aircraft components are subjected to complex hybrid variable loads during service, and the mechanical properties of composite/metal bolted joint directly affect the overall safety of aircraft structures. Research on composite/metal bolted joint and their mechanical properties has also become a topic of general interests. This article reviews the current research status of aeronautical composite/metal bolted joint and its mechanical properties and looks forward to future research directions.Design/methodology/approachThis article reviews the research progress on static strength failure and fatigue failure of composite/metal bolted joint, focusing on exploring failure analysis and prediction methods from the perspective of the theoretical models. At the same time, the influence and correlation mechanism of hole-making quality and assembly accuracy on the mechanical properties of their connections are summarized from the hole-making processes and damage of composite/metal stacked structures.FindingsThe progressive damage analysis method can accurately analyze and predict the static strength failure of composite/metal stacked bolted joint structures by establishing a stress analysis model combined with composite material performance degradation schemes and failure criteria. The use of mature metal material fatigue cumulative damage models and composite material fatigue progressive damage analysis methods can effectively predict the fatigue of composite/metal bolted joints. The geometric errors such as aperture accuracy and holes perpendicularity have the most significant impact on the connection performance, and their mechanical responses mainly include ultimate strength, bearing stiffness, secondary bending effect and fatigue life.Research limitations/implicationsCurrent research on the theoretical prediction of the mechanical properties of composite/metal bolted joints is mainly based on ideal fits with no gaps or uniform gaps in the thickness direction, without considering the hole shape characteristics generated by stacked drilling. At the same time, the service performance evaluation of composite/metal stacked bolted joints structures is currently limited to static strength and fatigue failure tests of the sample-level components and needs to be improved and verified in higher complexity structures. At the same time, it also needs to be extended to the mechanical performance research under more complex forms of the external loads in more environments.Originality/valueThe mechanical performance of the connection structure directly affects the overall structural safety of the aircraft. Many scholars actively explore the theoretical prediction methods for static strength and fatigue failure of composite/metal bolted joints as well as the impact of hole-making accuracy on their mechanical properties. This article provides an original overview of the current research status of aeronautical composite/metal bolted joint and its mechanical properties, with a focus on exploring the failure analysis and prediction methods from the perspective of theoretical models for static strength and fatigue failure of composite/metal bolt joints and looks forward to future research directions.

Development of accurate contour residual stress measurement technique for sustainable structural integrity assessment in additive manufacturing

Abstract Accurate analysis of residual stress present within an engineering component plays a fundamental role to its sustainable structural integrity assessment. This is particularly important for a safety critical component within the power generation sectors, aerospace, and oil and gas industries. The accurate stress analysis not only allows operators to determine the life remaining in a component but also avoid over-conservative estimates and thereby contribute to life extension of engineering plants and components. By utilizing and unifying multiple residual stress analysis tools of different nature a robust and more accurate method of stress analysis is achieved. The main aim of the current study focusses on the development and optimization of a robust residual stress tool based on the contour technique to accurately analyse inherent stress in an engineering component.