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sensorsArticleOn the Sensing and Calibration of Residual Stresses Measurements in the Incremental Hole-Drilling MethodMohamed M. A. Ammar 1,2, , Bijan Shirinzadeh 1 , Kai Zhong Lai 1 and Weichen WeiRobotics and Mechatronics Investigation Laboratory, Division of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, Australia Department of Mechanical Engineering, Faculty of Engineering, Alexandria University, Alexandria 11432, Egypt Correspondence: [email protected]: Ammar, M.M.A.; Shirinzadeh, B.; Lai, K.Z.; Wei, W. On the Sensing and Calibration of Residual Stresses Measurements inside the Incremental Hole-Drilling Technique. Sensors 2021, 21, 7447. https://doi.org/10.3390/s21227447 Academic Editors: Chris Karayannis and Roberto Teti Received: 14 September 2021 Accepted: four November 2021 Published: 9 NovemberAbstract: The current study presents 3 calibration approaches for the hole-drilling method (HDM). A total of 72 finite element models and 144 simulations were established to calibrate the measurements of the strain sensors. The first strategy assumed the stresses acted on the boundaries from the drilled hole and hence analyzed the surrounding displacements field. The second analysis regarded the loads around the outer surfaces on the specimen when measuring the strains’ differences between the model with and with no the drilled hole. The third method was additional comprehensive since it deemed the mechanical and thermal effects with the drilling operations. The proposed approaches had been applied to two distinct components (AISI 1045 and CFRP). The steel specimens have been machined working with a CNC lathe although the composite laminates were manufactured utilizing the robotic fiber placement (RFP) procedure. Subsequently, the residual stresses (RSs) had been measured using the HDM. The obtained information were compared with X-ray diffraction measurements for validation. The outcomes showed much better estimation of your RSs when utilizing the third approach and clear underestimation in the stresses utilizing the second method. A divergence in RSs values in between the 3 approaches was also detected when measuring the stresses within the internal layers in the composite laminates. Keywords: residual stresses; incremental hole-drilling; finite element modeling (fem); robotic fiber placement (RFP)1. Introduction Manufacturing and processing supplies are deemed the main sources of internal stresses (i.e., residual stresses (RSs)) inside structures. The induced RSs are certainly one of one of the most crucial parameters of surface integrity, as they are able to affect the high-quality in the final solutions. The fatigue life, brittle fracture process, di.
