On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method
The current study presents three calibration approaches for the hole-drilling method (HDM). A total of 72 finite element models and 144 simulations were established to calibrate the measurements of the strain sensors. The first approach assumed the stresses acted on the boundaries of the drilled hol...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-11-01
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| Series: | Sensors |
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| Online Access: | https://www.mdpi.com/1424-8220/21/22/7447 |
| _version_ | 1797508556818219008 |
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| author | Mohamed M. A. Ammar Bijan Shirinzadeh Kai Zhong Lai Weichen Wei |
| author_facet | Mohamed M. A. Ammar Bijan Shirinzadeh Kai Zhong Lai Weichen Wei |
| author_sort | Mohamed M. A. Ammar |
| collection | DOAJ |
| description | The current study presents three calibration approaches for the hole-drilling method (HDM). A total of 72 finite element models and 144 simulations were established to calibrate the measurements of the strain sensors. The first approach assumed the stresses acted on the boundaries of the drilled hole and thus analyzed the surrounding displacements field. The second analysis considered the loads on the outer surfaces of the specimen while measuring the strains’ differences between the model with and without the drilled hole. The third approach was more comprehensive as it considered the mechanical and thermal effects of the drilling operations. The proposed approaches were applied to two different materials (AISI 1045 and CFRP). The steel specimens were machined using a CNC lathe while the composite laminates were manufactured using the robotic fiber placement (RFP) process. Subsequently, the residual stresses (RSs) were measured using the HDM. The obtained data were compared with X-ray diffraction measurements for validation. The results showed better estimation of the RSs when utilizing the third approach and clear underestimation of the stresses using the second approach. A divergence in RSs values between the three approaches was also detected when measuring the stresses in the internal layers of the composite laminates. |
| first_indexed | 2024-03-10T05:05:37Z |
| format | Article |
| id | doaj.art-fce7a49a39a245df9b19e5881bbcd807 |
| institution | Directory Open Access Journal |
| issn | 1424-8220 |
| language | English |
| last_indexed | 2024-03-10T05:05:37Z |
| publishDate | 2021-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj.art-fce7a49a39a245df9b19e5881bbcd8072023-11-23T01:23:23ZengMDPI AGSensors1424-82202021-11-012122744710.3390/s21227447On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling MethodMohamed M. A. Ammar0Bijan Shirinzadeh1Kai Zhong Lai2Weichen Wei3Robotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, AustraliaRobotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, AustraliaRobotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, AustraliaRobotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, AustraliaThe current study presents three calibration approaches for the hole-drilling method (HDM). A total of 72 finite element models and 144 simulations were established to calibrate the measurements of the strain sensors. The first approach assumed the stresses acted on the boundaries of the drilled hole and thus analyzed the surrounding displacements field. The second analysis considered the loads on the outer surfaces of the specimen while measuring the strains’ differences between the model with and without the drilled hole. The third approach was more comprehensive as it considered the mechanical and thermal effects of the drilling operations. The proposed approaches were applied to two different materials (AISI 1045 and CFRP). The steel specimens were machined using a CNC lathe while the composite laminates were manufactured using the robotic fiber placement (RFP) process. Subsequently, the residual stresses (RSs) were measured using the HDM. The obtained data were compared with X-ray diffraction measurements for validation. The results showed better estimation of the RSs when utilizing the third approach and clear underestimation of the stresses using the second approach. A divergence in RSs values between the three approaches was also detected when measuring the stresses in the internal layers of the composite laminates.https://www.mdpi.com/1424-8220/21/22/7447residual stressesincremental hole-drillingfinite element modeling (fem)robotic fiber placement (RFP) |
| spellingShingle | Mohamed M. A. Ammar Bijan Shirinzadeh Kai Zhong Lai Weichen Wei On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method Sensors residual stresses incremental hole-drilling finite element modeling (fem) robotic fiber placement (RFP) |
| title | On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method |
| title_full | On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method |
| title_fullStr | On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method |
| title_full_unstemmed | On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method |
| title_short | On the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling Method |
| title_sort | on the sensing and calibration of residual stresses measurements in the incremental hole drilling method |
| topic | residual stresses incremental hole-drilling finite element modeling (fem) robotic fiber placement (RFP) |
| url | https://www.mdpi.com/1424-8220/21/22/7447 |
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