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<p>Manufacturing processes generate residual stresses that superimpose on in-service loads. Their accurate assessment is essential for the optimal design of structures, particularly with respect to fatigue and buckling. In the absence of reliable measurements, generic loading assumptions, which can be highly conservative, are often applied for industrial applications. While many techniques are available for near-surface characterization, only a limited number of methods allow for through-thickness residual stress evaluation in thick components (&gt;10&#xa0;mm), such as nuclear pressure vessels or ship structures. Among these, the Deep Hole Drilling technique offers the additional advantage of being applicable in situ without relocating the structure. The method consists of analyzing the diameter variation of a hole before and after its extraction from the structure to assess the released stresses through post-processing. In this paper, two post-processing approaches are compared: a standard analytical method based on the assumption of an independent stack of infinite plates, and a numerical reconstruction approach based on eigenstrain concepts requiring a finite element model. The selected case for this study is a beam subjected to four-point bending, generating a characteristic Z-shaped residual stress profile with strong stress gradient variations. A parametric numerical study is performed to assess the influence of drilling and trepanning diameters on stress reconstruction accuracy using ideal (noise-free) diameter variations. An experimental application is also conducted to validate the numerical findings. The results show that the analytical approach systematically underestimates peak stresses, with errors increasing with hole diameter due to the independence assumption, and may even predict incorrect stress signs when the infinite plate hypothesis is not satisfied. In contrast, the eigenstrain-based method provides more accurate peak stress estimation across configurations and inherently accounts for the actual geometry, avoiding sign errors.</p>

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Assessment of Eigenstrain-Based Post-treatment for Deep Hole Drilling Residual Stress Measurements

  • 期刊论文

  • 发表日期：

    2026年7月30日

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  • Kévin Faucon,
  • Bruno Levieil,
  • Sylvain Moyne,
  • Cédric Bain,
  • Florent Bridier,
  • Anthony Ezanno,
  • Cédric Doudard

摘要

Manufacturing processes generate residual stresses that superimpose on in-service loads. Their accurate assessment is essential for the optimal design of structures, particularly with respect to fatigue and buckling. In the absence of reliable measurements, generic loading assumptions, which can be highly conservative, are often applied for industrial applications. While many techniques are available for near-surface characterization, only a limited number of methods allow for through-thickness residual stress evaluation in thick components (>10 mm), such as nuclear pressure vessels or ship structures. Among these, the Deep Hole Drilling technique offers the additional advantage of being applicable in situ without relocating the structure. The method consists of analyzing the diameter variation of a hole before and after its extraction from the structure to assess the released stresses through post-processing. In this paper, two post-processing approaches are compared: a standard analytical method based on the assumption of an independent stack of infinite plates, and a numerical reconstruction approach based on eigenstrain concepts requiring a finite element model. The selected case for this study is a beam subjected to four-point bending, generating a characteristic Z-shaped residual stress profile with strong stress gradient variations. A parametric numerical study is performed to assess the influence of drilling and trepanning diameters on stress reconstruction accuracy using ideal (noise-free) diameter variations. An experimental application is also conducted to validate the numerical findings. The results show that the analytical approach systematically underestimates peak stresses, with errors increasing with hole diameter due to the independence assumption, and may even predict incorrect stress signs when the infinite plate hypothesis is not satisfied. In contrast, the eigenstrain-based method provides more accurate peak stress estimation across configurations and inherently accounts for the actual geometry, avoiding sign errors.