Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels
Cold expansion technology is an extended method used in aeronautics to increase fatigue life of holes and hence extending inspection intervals. During the cold expansion process, a mechanical mandrel is forced to pass along the hole generating compressive residual hoop stresses. The most widely acce...
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MDPI AG
2020-12-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/13/23/5536 |
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| author | David Curto-Cárdenas Jose Calaf-Chica Pedro Miguel Bravo Díez Mónica Preciado Calzada Maria-Jose Garcia-Tarrago |
| author_facet | David Curto-Cárdenas Jose Calaf-Chica Pedro Miguel Bravo Díez Mónica Preciado Calzada Maria-Jose Garcia-Tarrago |
| author_sort | David Curto-Cárdenas |
| collection | DOAJ |
| description | Cold expansion technology is an extended method used in aeronautics to increase fatigue life of holes and hence extending inspection intervals. During the cold expansion process, a mechanical mandrel is forced to pass along the hole generating compressive residual hoop stresses. The most widely accepted geometry for this mandrel is the tapered one and simpler options like balls have generally been rejected based on the non-conforming residual hoop stresses derived from their use. In this investigation a novelty process using multiple balls with incremental interference, instead of a single one, was simulated. Experimental tests were performed to validate the finite element method (FEM) models and residual hoop stresses from multiple balls simulation were compared with one ball and tapered mandrel simulations. Results showed that the use of three incremental balls significantly reduced the magnitude of non-conforming residual hoop stresses and the extension of these detrimental zone. |
| first_indexed | 2024-03-10T14:18:49Z |
| format | Article |
| id | doaj.art-cbe02ca558ed4ae8a5cc7fe973814ecf |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T14:18:49Z |
| publishDate | 2020-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-cbe02ca558ed4ae8a5cc7fe973814ecf2023-11-20T23:34:26ZengMDPI AGMaterials1996-19442020-12-011323553610.3390/ma13235536Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered MandrelsDavid Curto-Cárdenas0Jose Calaf-Chica1Pedro Miguel Bravo Díez2Mónica Preciado Calzada3Maria-Jose Garcia-Tarrago4CIMa Research Team, Department of Civil Engineering, University of Burgos, Av. Cantabria s/n, 09006 Burgos, SpainCIMa Research Team, Department of Civil Engineering, University of Burgos, Av. Cantabria s/n, 09006 Burgos, SpainCIMa Research Team, Department of Civil Engineering, University of Burgos, Av. Cantabria s/n, 09006 Burgos, SpainCIMa Research Team, Department of Civil Engineering, University of Burgos, Av. Cantabria s/n, 09006 Burgos, SpainDepartment of Electromechanical Engineering, University of Burgos, Av. Cantabria s/n, 09006 Burgos, SpainCold expansion technology is an extended method used in aeronautics to increase fatigue life of holes and hence extending inspection intervals. During the cold expansion process, a mechanical mandrel is forced to pass along the hole generating compressive residual hoop stresses. The most widely accepted geometry for this mandrel is the tapered one and simpler options like balls have generally been rejected based on the non-conforming residual hoop stresses derived from their use. In this investigation a novelty process using multiple balls with incremental interference, instead of a single one, was simulated. Experimental tests were performed to validate the finite element method (FEM) models and residual hoop stresses from multiple balls simulation were compared with one ball and tapered mandrel simulations. Results showed that the use of three incremental balls significantly reduced the magnitude of non-conforming residual hoop stresses and the extension of these detrimental zone.https://www.mdpi.com/1996-1944/13/23/5536cold expansionswagingballaeronauticalsimulationexperimental |
| spellingShingle | David Curto-Cárdenas Jose Calaf-Chica Pedro Miguel Bravo Díez Mónica Preciado Calzada Maria-Jose Garcia-Tarrago Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels Materials cold expansion swaging ball aeronautical simulation experimental |
| title | Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels |
| title_full | Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels |
| title_fullStr | Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels |
| title_full_unstemmed | Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels |
| title_short | Cold Expansion Process with Multiple Balls—Numerical Simulation and Comparison with Single Ball and Tapered Mandrels |
| title_sort | cold expansion process with multiple balls numerical simulation and comparison with single ball and tapered mandrels |
| topic | cold expansion swaging ball aeronautical simulation experimental |
| url | https://www.mdpi.com/1996-1944/13/23/5536 |
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