Experimental measurement of residual stresses in cold-drawn aluminum tubes
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Abstract
One of the most common sources of residual stresses is the non-uniform plastic deformation encountered in metal-forming operations. Determination of residual stresses is of major importance in many processes as well as precision equipment components. All destructive techniques, such as hole-drilling and boring-out techniques, are based on the principle of removing part of the stressed material and measuring the resulting strains as the material adjusts its shape to maintain equilibrium. The purpose of this study was to measure the residual stress distributions in cold-drawn aluminum tubes via a modified Sachs boring-out technique utilizing electrochemical machining (ECM) as the means of material removal. Electrochemical machining (electropolishing) was performed on the inner surface of the tubes while measuring the developed strains at the outer surface. Material removal by electropolishing technique was found suitable enough to produce a homogeneous and damage-free surface for measurement of required strains.