A procedure for evaluating high residual stresses using the blind hole drilling method, including the effect of plasticity

When the blind hole drilling method is used to evaluate high residual stresses in a metallic component, plastic relaxed strain can be produced in the hole region because of the stress concentration that causes the local stresses to reach yielding. By assuming a linear-elastic behaviour of the material, a significant error can result. The present paper analyses the phenomenon of the plasticity locally induced by the introduction of the hole and proposes a procedure to take into account its effects on the residual stress evaluation. The correcting procedure has been developed by elaborating a large database of elastic-plastic finite element analyses performed considering a wide range of material properties and testing parameters, including all the strain gauge rosettes commonly used. As plasticity induces non-linearity in the relationship between residual stress and relaxed strain, the superposition principle cannot be applied, so the correction is limited to uniform in-depth residual stress fields. However, four hole depths were considered and the related correcting procedures were provided. When variable through thickness residual stress is expected, and high residual stress is confined near the surface region, the correction procedure can be applied to an initial limited depth.