Verification and Application of a New 3D Finite Element Approach to Model the Residual Stress Depth Profile after Autofrettage and Consecutive Reaming

Manufacturing processes which selectively induce pronounced compressive residual stresses such as hydraulic Autofrettage are gaining increasing importance. Especially for internally pressurized components, the compressive residual stresses are used as design tool in order to increase the fatigue strength. However, the final residual stress depth profile is a result of the whole technical process chain. This paper presents results of two 3D finite element models. First, DEFORM is used to model the temperature generation during reaming. For the considered case study, it becomes evident that reaming can be reduced to the mechanical residual stress formation mechanisms. Second, Abaqus/Explicit is used to model the final residual stress depth profile after Autofrettage and consecutive reaming. The simulations are verified by experiments and detailed X-ray residual stress measurements.