Residual Stress Measurements of Cold-Forged Ball Studs by the Contour Method

Residual Stress Measurements of Cold-Forged Ball Studs by the Contour Method

In this study, residual stresses of cold-forged ball studs were investigated by the contour method with using widely available wire-Electro-Discharging Machine (wire-EDM) and Coordinate Measuring Machine (CMM). After the wire-EDM cutting, one of the steps of the contour method, it was revealed that...

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Bibliographic Details
Published in:Experimental techniques (Westport, Conn.) Vol. 46; no. 6; pp. 919 - 930
Main Authors: Toparli, M. B., Kılınçdemir, N. E., Yurtdaş, S., Tanrıkulu, B., İnce, U.
Format: Journal Article Magazine Article
Language:English
Published: Cham Springer International Publishing 2022
Springer Nature B.V
Subjects:
Characterization and Evaluation of Materials
Chemistry and Materials Science
Cold forging
Compressive properties
Contour forging
Coordinate measuring machines
Errors
Heat treatment
Machine tools
Materials Science
Research Paper
Residual stress
Studs
Wire
Cold forging
Ball stud
Contour method
Cutting-induced artefacts
Residual stress
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Summary:In this study, residual stresses of cold-forged ball studs were investigated by the contour method with using widely available wire-Electro-Discharging Machine (wire-EDM) and Coordinate Measuring Machine (CMM). After the wire-EDM cutting, one of the steps of the contour method, it was revealed that the surface contour data was affected from the cutting step. Therefore, to increase the accuracy of the measured residual stresses, one of the ball studs were heat-treated to normalize residual stresses due to cold forging. The contour data of the heat-treated sample was subtracted from the as-forged surface contour to eliminate any cutting-induced artefacts. The final residual stress profiles suggested that the subtracting procedure minimized the cutting errors. In addition, a new classification approach for the cutting-induced errors for the contour method was introduced. According to final stress maps obtained by the contour method, it was revealed that high compressive residual stresses were obtained at the socket regions of the ball studs, as expected. Balancing tensile residual stresses were observed at the inner regions.
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ISSN:0732-8818
1747-1567
DOI:10.1007/s40799-021-00521-w