TY - JOUR

T1 - Analysis of tailored residual stress fields of deep rolled AA2024 sheets

AU - Lehmann, Jonas

AU - Pöltl, Dominik

AU - Esterl, Fabian

AU - Kashaev, Nikolai

AU - Ben Khalifa, Noomane

N1 - Publisher Copyright: © The Author(s) 2025.

PY - 2025/9

Y1 - 2025/9

N2 - Deep rolling has advantages to modify local residual stresses in AA2024 sheets. A previous study about deep rolling for tailoring residual stresses [1] is extended in order to examine the homogeneity of the residual stress field. For the experimental residual stress analysis, the incremental hole drilling method with electronic speckle pattern interferometry is used with two different drill diameters. A numerical evaluation scheme is applied to simulation results of an existing process model with the aim of mimicking the experimental analysis technique. The volume under the deep rolled surface is classified in three sections based on the history of the process. Comparisons between experimental and simulative results yield a number of observations: Deeper evaluation with higher driller diameter does not come at a price of higher in-plane averaging of spatial gradients. Simulating a number of paths lower than those of the experiments shows similar homogeneity of the simulatively and experimentally analyzed stress field. Stretching the evaluation scheme from cylindrical volumes to cubic volumes shows very good qualitative agreement and validates the choice of classification.

AB - Deep rolling has advantages to modify local residual stresses in AA2024 sheets. A previous study about deep rolling for tailoring residual stresses [1] is extended in order to examine the homogeneity of the residual stress field. For the experimental residual stress analysis, the incremental hole drilling method with electronic speckle pattern interferometry is used with two different drill diameters. A numerical evaluation scheme is applied to simulation results of an existing process model with the aim of mimicking the experimental analysis technique. The volume under the deep rolled surface is classified in three sections based on the history of the process. Comparisons between experimental and simulative results yield a number of observations: Deeper evaluation with higher driller diameter does not come at a price of higher in-plane averaging of spatial gradients. Simulating a number of paths lower than those of the experiments shows similar homogeneity of the simulatively and experimentally analyzed stress field. Stretching the evaluation scheme from cylindrical volumes to cubic volumes shows very good qualitative agreement and validates the choice of classification.

KW - Aluminum alloy

KW - Deep rolling

KW - Finite element analysis

KW - Residual stress analysis

KW - Residual stress modification

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=105012285805&partnerID=8YFLogxK

U2 - 10.1007/s12289-025-01933-4

DO - 10.1007/s12289-025-01933-4

M3 - Journal articles

AN - SCOPUS:105012285805

VL - 18

JO - International Journal of Material Forming

JF - International Journal of Material Forming

SN - 1960-6206

IS - 3

M1 - 66

ER -