ALBERT

Description: There is no simple and perfect way to measure residual stresses in metal parts that have been welded or deformed to make complex structures such as pressure vessels and aircraft, yet these locked-in stresses can contribute to structural failure by fatigue and fracture. However, one proven and tested technique for determining the internal stress of a metal part is to drill a test hole while measuring the relieved strains around the hole, such as the hole-drilling strain gage method described in ASTM E 837. The program HOLEGAGE processes strain gage data and provides additional calculations of internal stress variations that are not obtained with standard E 837 analysis methods. The typical application of the technique uses a three gage rosette with a special hole-drilling fixture for drilling a hole through the center of the rosette to produce a hole with very small gage pattern eccentricity error. Another device is used to control the drilling and halt the drill at controlled depth steps. At each step, strains from all three strain gages are recorded. The influence coefficients used by HOLEGAGE to compute stresses from relieved hole strains were developed by published finite element method studies of thick plates for specific hole sizes and depths. The program uses a parabolic fit and an interpolating scheme to project the coefficients to other hole sizes and depths. Additionally, published experimental data are used to extend the coefficients to relatively thin plates. These influence coefficients are used to compute the stresses in the original part from the strain data. HOLEGAGE will compute interior planar stresses using strain data from each drilled hole depth layer. Planar stresses may be computed in three ways including: a least squares fit for a linear variation with depth, an integral method to give incremental stress data for each layer, or by a linear fit to the integral data (with some surface data points omitted) to predict surface stresses before strain gage sanding preparations introduced additional residual stresses. Options are included for estimating the effect of hole eccentricity on calculations, smoothing noise from the strain data, and inputting the program data either interactively or from a data file. HOLEGAGE was written in FORTRAN 77 for DEC VAX computers under VMS, and is transportable except for system-unique TIME and DATE system calls. The program requires 54K of main memory and was developed in 1990. The program is available on a 9-track 1600 BPI VAX BACKUP format magnetic tape (standard media) or a TK50 tape cartridge. The documentation is included on the tape. DEC VAX and VMS are trademarks of Digital Equipment Corporation.