Stress Concentration Factors in Excavation Repairs of Surface Defects in Forgings and Castings

This paper provides an analytical formula for the theoretical stress concentration factor in a common type of excavation repair for large forgings and castings. Mechanical components obtained with these processes are often subjected to superficial defects. As the rejection of such pieces is out of q...

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Bibliographic Details
Published in:Materials 2022-02, Vol.15 (5), p.1705
Main Authors: Rebora, Alessandro, Torre, Giorgio, Vernassa, Gianluca
Format: Article
Language:English
Subjects:
Accuracy
Boundary conditions
Casting defects
Castings
Defects
Excavation
Finite element method
Forgings
Functions (mathematics)
Mathematical analysis
Mechanical components
Parameters
Polynomials
Repair
Stress concentration
Stress state
Surface defects
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Summary:This paper provides an analytical formula for the theoretical stress concentration factor in a common type of excavation repair for large forgings and castings. Mechanical components obtained with these processes are often subjected to superficial defects. As the rejection of such pieces is out of question, given the relevant size and costs associated with them, usual industrial practice consists in the removal of the defect and a portion of the surrounding material through milling processes. The authors have selected a reference geometry of the excavation to be left on the mechanical pieces, which can be easily controllable in practice by three operating parameters. Then, the domain of existence of such a repair was investigated on a sequence of discrete points, by means of FEA, obtaining for each, the values of the stress concentration factor K . Finally, through polynomial regression, the K functions have been accurately approximated by a sixth degree polynomial formulation, which, given a triplet of dimensional geometric parameters, is able to compute the stress concentration factor K with an error that never exceeds 8%.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma15051705