Stress Concentration Effects on Industrial Components
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TECHNICAL ARTICLE—PEER-REVIEWED
Stress Concentration Effects on Industrial Components G. Viau • R. Ortega • L. Boccanera E. Pasquali • H. Sbuttoni
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Submitted: 5 May 2010 / in revised form: 1 July 2010 / Published online: 23 July 2010 Ó ASM International 2010
Abstract This article demonstrates the importance of stress concentrations on the life of industrial components. The design review and analysis of maintenance tasks (repair) can foresee and avoid such harmful design defects and/or bad habits that can reduce component life in service. Three steel shop examples are mentioned and details of these selected situations are analysed using metallurgy and finite element tools. Keywords Stress concentrations Failure analysis Fractography Metallography Finite element Fatigue
Frequently, machine parts and industrial components have surface discontinuities (produced during repair or by design) which act as stress concentrators during the service life. High stress concentrations are not always avoidable and may lead to failure of the part if not controlled adequately. However, stress concentrators on components can generally be minimized or mitigated by following three relatively standard practices. Consideration and control of these practices will increase the life service of components and the operating efficiency of the system. (i)
Introduction Changes in the section size or configuration on stressed components modify the load lines in predictable manners [1]. G. Viau R. Ortega L. Boccanera (&) Ternium-Centro Siderurgico General Savio, Casilla de Correo 801, 2900 Ramallo, Buenos Aires, Argentina e-mail: [email protected]; [email protected] G. Viau e-mail: [email protected] R. Ortega e-mail: [email protected] E. Pasquali H. Sbuttoni Instituto Argentino de Siderurgia, Av. Central y Calle 19 Oeste, 2900 San Nicola´s, Buenos Aires, Argentina e-mail: [email protected] H. Sbuttoni e-mail: [email protected]
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(ii)
(iii)
Design: By working on design aspects, it is possible to modify the stress concentration factor ‘kt’, present in each design. There are numerous techniques to modify the design of the part and thereby achieve a kt reduction. Material selection: It is very important to control the metallurgical characteristics of the metal which will be used to produce the piece. The chemical composition, the metallographic structure, and the inclusion content and distribution determine the intrinsic properties of the metal. Therefore, these are important factors to be considered when attempting to prolong the service life of a component. Component fabrication: Fabrication is also a fundamental factor that influences the life of the component. Not only are the thermal–mechanical processes (casting, forging, rolling, or machining) used to provide the bulk material important but the processes of welding and heat treatment received by the piece during fabrication will also impact the component properties.
As an example, the fatigue resistance of a component
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