Residual Stresses & Fatigue LiResidual Stress Residual Stresses are stresses that remain in a specimen after exter removed. » It may be desirable or undesirable, » For eg : Laser peening imparts deep beneficial compressive residual metal components such as Turbine engine ,fan blades & it is used in glass to allow for large ,thin ,crack & scratch resistant glass displays, smartphones. o Fig: Toughened Glass for Smart PhonesWhat Does Fatigue Life Means? > Fatigue Life - The fatigue limit or the fatigue life which is also known as e limit is the stress level below which any infinite number of loading cycles applied to a material without causing fatigue failure. \ > Overtime, fatigue failure can lead to safety issues & the loss of critical infrastructures. > An example of fatigue failure was the airline crashes of the De Havilland C 1954, Three of these passenger jets broke up mid-air and crashed within a si year. Sharp corners around the plane’s window openings were found to stress concentrators which initiated cracks.a Scope of Present Study | ‘Many manufacturing processes can induce residual stresses in components. These residual stresses influence the mean stress during cyclic loading and so can influence the fatigue life. The _ present study focuses on types of residual stresses and its effect on fatigue life. Controlling residual stress and its causes due to which they arise while manufacturing process. OBJECTIVES To study and understand residual stress and fatigue life. To study and understand causes, effects and controlling ofResidual Stress jidual Stresses are stresses that remains in a solid material after the original has been removed. idual stresses can be tensile or compressive. In fact, tensile and compressive co-exist within a component. uses of residual stress : Plastic Deformation & Non-plastic Deformation (Bending or Drawing). Residual stress due to temperature variations : «In parts cooled from elevated temperatures, residual stresses are caused by variations in the metal during cooling. * Cooling from elevated temperatures occurs during heat treating and welding. + Thermal contraction develops non-uniform stress due to different rates of cooli the surface and interior of the metal.Effects and controlling: Effects of residual stress: >Resioual stresses ean be banalical or dtrimantal, depending on whether me stress tensse ar compressive. | "Tensie residual stresses can be large encugh to cause component distortion or cracking. Also, faogue and stress ie presence of tensile stesses. ‘Surface residual compressive stresses are generally hlpful because they reduce the effects of applied enile ‘this can be achieved through machanical treatment, stress ral heat reaiment, contol of het weating processes, and htachanical treatments such as shat peening, light old rang, etching. and small amounts of compressing are used 1 compressive residual stress althe surface of @ component. \ ntoo, etoys ean be selected that aay for slower eoaling rates to be used, while stl geting the desired pase ‘example, for carbon size! eamponents to be through hardanes, low-alloy carbon staels enable the use of slower coating plain carbon steels,Fatigue Life : > Fatigue life is a mechanical and scientific term that relates to how long an object | or material will last before completely failing because of concentrated stresses. > There are a number of different factors that can influence fatigue life including the type of material being used, its structure, its shape and temperature changes. | > In most cases, fatigue life is calculated as the number of stress cycles that an ‘object or material can handle before the failure. © When a material is put into use, the design can increase the stress that is put on the For instance, certain sharper angles, such as the comers in a square object, can be a higher stress area than a rounded area, which disperses the weight and stress of a over a larger area,Case Study A large number of fatigue tests for Aluminium alloy 5754 shows that the fatigue failure of welding spot is mainly caused by the defects of welding process, so the welding spot defect have a big impact on fatigue life prediction for welded parts. How it occurs ? It occurs due to residual stresses and cyclic loadings which causes micro crack formation inside specimen and as a result fracture occurs. The residual stresses may be Compressive or tensile or may be both existing in the Specimen.Figure 1 Figure 2 Fig 1, fig 2 is respectively static analysis result for complete specim specimens with defects in the ansys workbench software. By contrast, found that position of stress concentration is around moll the spot welding. Namely place is the location of the fatigue failure under cyclic | * The maximum stress of the stress concentration of defect speci nearly three times than no defect specimen.Conclusion In many cases reduce stress analysis play an important role in performance of materials, parts, and structural elements. Their the engineering properties of materials such as fatigue and fi corrosion resistance, and dimensional stability can be considerabl Residual stresses should therefore be taken into account during design ,fatigue assessment, and manufacturing of parts and stru elements. Analysis of the failure mode of welding spot Under cyclic load, get the stress concentration location of weldii predict the fatigue life of two kinds of different welding parts, dis influence of defects for the fatigue life of welding parts. For fui improving welding technology, it points out the direction and time it let the foundation for the next step research.Reference