MNSMS  Vol.4 No.1 , January 2014
Finite Element Method Investigation of the Effect of Cold Expansion Process on Fatigue Crack Growth in 6082 Aluminum Alloy
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.

Cite this paper
A. Aid, Z. Semari and M. Benguediab, "Finite Element Method Investigation of the Effect of Cold Expansion Process on Fatigue Crack Growth in 6082 Aluminum Alloy," Modeling and Numerical Simulation of Material Science, Vol. 4 No. 1, 2014, pp. 25-31. doi: 10.4236/mnsms.2014.41005.
References
[1]   Y. S. Liu, X. J. Shao, J. Liu and Z. F. Yue, “Finite Element Method and Experimental Investigation on the Residual Stress Fields and Fatigue Performance of Cold Expansion Hole,” Materials and Design, Vol. 31, No. 3, 2010, pp. 1208-1215. http://dx.doi.org/10.1016/j.matdes.2009.09.031

[2]   V. Nigrelli and S. Pasta, “Finite-Element Simulation of Residual Stress Induced by Split-Sleeve Cold-Expansion Process of Holes,” Journal of Material Processing Technology, Vol. 205, No. 1-3, 2008, pp. 290-296. http://dx.doi.org/10.1016/j.jmatprotec.2007.11.207

[3]   A. Amrouche, G. Mesmacque, S. Garcia and A. Talha, “Cold Expansion Effect on the Initiation and the Propagation of the Fatigue Crack,” International Journal of Fatigue, Vol. 25, No. 9, 2003, pp. 949-954. http://dx.doi.org/10.1016/S0142-1123(03)00127-0

[4]   J. Bertrand and C. Fabrice, “Prévision de la Fissuration par Fatigue en préSence de Contraintes Résiduelles,” Méc. & Industries, Vol. 6, 2005, pp. 75-88.

[5]   D. Stefanescu, J. R. Santisteban, L. Edwards and M. E. Fitzpatrick, “Residual Stress Measurement and Fatigue Crack Growth Prediction after Cold Expansion of Cracked Fastener Holes,” Journal of Aerospace Engineering, Vol. 17, No. 91, 2004, pp. 893-1321.

[6]   M. Toparli and T. Aksoy, “Effect of the Residual Stresses on the Fatigue Crack Growth Behaviour at Fastener Holes,” Materials Science and Engineering A, Vol. 225, No. 1-2, 1997, pp. 196-203. http://dx.doi.org/10.1016/S0921-5093(96)10875-3

[7]   S. Pasta, “Fatigue Crack Propagation from a Cold-Worked Hole,” Engineering Fracture Mechanics, Vol. 74, No. 9, 2007, pp. 1525-1538. http://dx.doi.org/10.1016/j.engfracmech.2006.08.006

[8]   X. Zhang and Z. Wang, “Fatigue Life Improvement in Fatigue-Aged Fastener Holes Using the Cold Expansion Technique,” International Journal of Fatigue, Vol. 25, No. 9-10, 2003, pp. 1249-1257. http://dx.doi.org/10.1016/S0142-1123(03)00152-X

[9]   X. Zhang and Z. Wang, “Predicting Fatigue Crack Growth Life for Cold-Worked Holes Based on Existing Closed-Form Residual Stress Models,” International Journal of Fatigue, Vol. 25, No. 9, 2003, pp. 1285-1291. http://dx.doi.org/10.1016/S0142-1123(03)00153-1

[10]   V. D. Lacarac, D. J. Smith and M. J. Pavier, “The Effect of Cold Expansion on Fatigue Crack Growth from Open Holes at Room and High Temperature,” International Journal of Fatigue, Vol. 23, No. 1, 2001, pp. 161-170. http://dx.doi.org/10.1016/S0142-1123(01)00125-6

[11]   H. D. Gopalakrishna, M. H. N. Narasimha, M. Krishna, M. S. Vinod and A. V. Suresh, “Cold Expansion of Holes and Resulting Fatigue Life Enhancement and Residual Stresses in Al2024T3 Alloy—An Experimental Study,” Engineering Failure Analysis, Vol. 17, No. 2, 2010, pp. 361-368. http://dx.doi.org/10.1016/j.engfailanal.2009.08.002

[12]   P. F. P de Matos, P. M. G. P. Moreira, I. Nedbal and P. M. S. T. de Castro, “Reconstitution of Fatigue Crack Growth in Al-Alloy 2024-T3 Open-Hole Specimens Using Microfractographic Techniques,” Engineering Fracture Mechanics, Vol. 72, No. 14, 2005, pp. 2232-2246. http://dx.doi.org/10.1016/j.engfracmech.2005.02.005

[13]   T. N. Chakherlou and J. Vogwell, “The Effect of Cold Expansion on Improving the Fatigue Life of Fastener Holes,” Engineering Failure Analysis, Vol. 10, No. 1, 2003, pp. 13-24. http://dx.doi.org/10.1016/S1350-6307(02)00028-6

[14]   A. Amrouchea, M. Su, A. Aid and G. Mesmacque, “Numerical Study of the Optimum Degree of Cold Expansion: Application for the Pre-Cracked Specimen with the Expanded Hole at the Crack Tip,” Journal of Materials Processing Technology, Vol. 197, No. 1-3, 2008, pp. 250-254.

[15]   D. L. Rich and L. F. Impellizzeri, “Fatigue Analysis of Cold-Worked and Interference Fit Fastener Holes. Cyclic Stress-Strain and Plastic Deformation Aspect of Fatigue Crack Growth,” ASTM STP 637 Amer. Soc. for Test and Mat, 1977, pp. 153-175.

[16]   J. E. LaRue, “The Influence of Residual Stress on Fatigue Crack Growth,” Master Thesis, Mississippi State University, Starkville, 2005.

[17]   M. Chobin, M. Anggit, K. Kazuo, I. Yoshiki and S. Akihide, “Crack Growth Arrest by Redirecting Crack Growth by Drilling Stop Holes and Inserting Pins into Them,” Engineering Failure Analysis, Vol. 16, No. 1, 2009, pp. 475-483. http://dx.doi.org/10.1016/j.engfailanal.2008.06.009

[18]   J. E. LaRue and S. R. Daniewicz. “Predicting the Effect of Residual Stress on Fatigue Crack Growth,” International Journal of Fatigue, Vol. 29, No. 3, 2007, pp. 508-515. http://dx.doi.org/10.1016/j.ijfatigue.2006.05.008

[19]   W. J. Keith and L. D. Martin, “Predicting Fatigue Crack Growth from a Pre-Yielded Hole,” International Journal of Fatigue, Vol. 31, No. 2, 2009, pp. 223-230. http://dx.doi.org/10.1016/j.ijfatigue.2008.09.007

[20]   ANSYS User’s Manuals, Revision 11.0, 2007.

[21]   C. S. Kusko, J. N. DuPont and A. R. Marder, “Influence of Stress Ratio on Fatigue Crack Propagation Behaviour of Stainless Steel Welds,” Welding Journal, Vol. 83, No. 2, 2004, pp. 59-64.

[22]   D. Kujawski, “Enhanced Model of Partial Crack Closure for Correlation of R-Ratio Effects in Aluminum Alloys,” International Journal of Fatigue, Vol. 23, No. 2, 2001, pp. 95-102. http://dx.doi.org/10.1016/S0142-1123(00)00085-2

[23]   J. A. Newman, “The Effects of Load Ratio on Threshold Fatigue Crack Growth of Aluminum Alloys,” Doctoral Thesis, Virginia University, Charlottesville, 2000.

[24]   N. Ramesh, “Fatigue Crack Growth under Residual Stresses around Holes,” Master Thesis, Mississippi State University, Charlottesville, 2005.

[25]   J. H. Underwood, L. P. Pook and J. K. Sharples, “Flaw Growth and Fracture,” ASTM STP 631 Amer. Soc. for Test and Mat 1977, pp. 402-4015.

[26]   S. Fukuda and Y. Tsuruta, “An Experimental Study of Redistribution of Welding Residual Stress,” Transactions of JWRI, Vol. 7, No. 2, 1978, pp. 67-72.

[27]   N. Chandawanich and W. N. Sharpe Jr., “An Experimental Study of Fatigue Crack Initiation and Growth from Cold Worked Holes,” Engineering Fracture Mechanics, Vol. 11, No. 4, 1979, pp. 609-620. http://dx.doi.org/10.1016/0013-7944(79)90122-X

[28]   Y. C. Lam and K. S. Lian, “Effect of Residual Stress and Its Redistribution on Fatigue Crack Growth,” Theoretical and Applied Fracture Mechanics, Vol. 12, No. 1, 1989, pp. 59-66. http://dx.doi.org/10.1016/0167-8442(89)90015-3

[29]   A. Todoroki and H. Kobayashi, “Prediction of Fatigue Crack Growth Rate in Residual Stress Fields,” Key Engng Mat. Fract Strength, Vol. 367, 1991, pp. 51-52.

[30]   S. Man, “Etude de l’Influence et de l’Optimisation du Degré d’Expansion à Froid dans les Mécanismes de Réamorçage d’Une Fissure: Etude Numerique et Expérimentale,” Doctoral Thesis, Université des Sciences et Technologies de Lille, Lille, 2005.

 
 
Top