The Contour Method Cutting Assumption: Error Minimization and Correction

The recently developed contour method can measure 2-D, cross-sectional residual-stress map. A part is cut in two using a precise and low-stress cutting technique such as electric discharge machining. The contours of the new surfaces created by the cut, which will not be flat if residual stresses are relaxed by the cutting, are then measured and used to calculate the original residual stresses. The precise nature of the assumption about the cut is presented theoretically and is evaluated experimentally. Simply assuming a flat cut is overly restrictive and misleading. The critical assumption is that the width of the cut, when measured in the original, undeformed configuration of the body is constant. Stresses at the cut tip during cutting cause the material to deform, which causes errors. The effect of such cutting errors on the measured stresses is presented. The important parameters are quantified. Experimental procedures for minimizing these errors are presented. An iterative finite element procedure to correct for the errors is also presented. The correction procedure is demonstrated on experimental data from a steel beam that was plastically bent to put in a known profile of residual stresses.

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