Integration of residual stresses in the design of mechanical parts

Abstract

This paper presents an original approach in mechanical design to integrate the manufacturing constraints in the final CAD model. A specific user-interface is proposed to integrate manufacturing constraints (for example tolerances) and manufacturing consequences (for example roughness or hardening) into the model. One of the important consequences of manufacturing processes is the generation of residual stresses into the part. An appropriate tool has been developed and used as a design tool to manage the global evolution of residual stresses in the mechanical part and to obtain the deformed geometry resulting from the applied manufacturing plan. These results could eventually be used in fatigue simulation. To support the model, a database is used for the integration of residual stresses from stored experimental results, analytical or numerical calculations. An example of a metal sheet, laminated and deformed by shot peening is given, the deformed geometry is rebuilt and compared to the experimental results.