Fatigue life prediction models for components subjected to manufacturing induced residual stresses

TLDR: A comprehensive study of the mechanical fatigue subject is presented, with particular focus on the residual stresses issue, as their impact on the fatigue life expectations, the manufacturing processes behind their formation, their measurement methods and the most preforming way to account them in the fatigueLife estimates.

Abstract: The residual stresses were proven to play a relevant role in the fatigue life expectations of components and specimens. It is well established that almost every manufacturing process to some extent leads to the residual or internal stress fields formation. The challenge is to properly account for these internal stress fields in the fatigue life prediction. In this essay a comprehensive study of the mechanical fatigue subject is presented, with particular focus on the residual stresses issue, as their impact on the fatigue life expectations, the manufacturing processes behind their formation, their measurement methods and the most preforming way to account them in the fatigue life estimates. The most challenging issues in terms of the residual stress simulation in fatigue are presented through the previous works found in literature and finally in this thesis my personal contribution was given in the development of a Python program for the optimized insertion of a residual stress field on a finite element model, which will be potentially employed at FCA Automobiles for research purpose.