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Two-dimensional Mapping of Bulk Residual Stress Using Cut Mouth Opening Displacement

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Background: Prior work described an approach for mapping the two-dimensional spatial distribution of biaxial residual stress in plate-like samples, the approach combining multiple slitting measurements with elastic stress analysis. Objective: This paper extends the prior work by applying a new variation of the slitting method that uses measurements of cut mouth opening displacement (CMOD) rather than back-face strain (BFS). Methods: First, CMOD slitting is validated using an experiment where: BFS and CMOD are measured simultaneously on the same sample during incremental slitting; two residual stress profiles are computed, one from the BFS data and a second from the CMOD data; and the two residual stress profiles are compared. Following validation, multiple adjacent CMOD slitting measurements are used to construct two-dimensional maps of residual stress in plates cut from quenched aluminum. Results: The two residual stress versus depth profiles, each computed separately from BFS or CMOD data, are in agreement, with compression near the plate boundaries (-150 MPa) and tension near the plate center (100 MPa); differences between the two stress profiles have a maximum of 25 MPa and a RMS of 7.2 MPa. Repeated biaxial residual stress mapping measurements show the CMOD technique is repeatable, and complementary contour method measurements show the mappings are valid. Aspects of CMOD and BFS deformations during slitting are also described and show they are generally complementary but that CMOD slitting is favorable in narrow samples.

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