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Residual stresses in machined and shrink-fitted assemblies

This paper presents measured and predicted residual stresses from two sets of shrinkfitted assemblies, each manufactured using an aluminium alloy and a cast iron. Residual stresses were measured using a combination of deep-hole drilling (DHD) and incremental centre hole drilling (ICHD) techniques. The ICHD method provided near surface residual stress measurements to depths up to about 1mm. The DHD method measured through thickness residual stresses along radial lines through the outer sleeve and into the shaft. Results are shown for the two assemblies and reveal residual stresses that are different from both simple analysis and finite element studies. For example, prior machining introduced near surface compressive residual stresses, that is then expected to be counteracted by the near surface tensile shrink-fit residual stresses. However, measurements reveal that this is not the case.