Residual Stresses Evaluation in Equal Channel Angular Rolled Al 5083 by IHD Technique: Investigation of Two Calculation Methods

Equal channel angular rolling (ECAR) method is one of the severe plastic deformation (SPD) processes which can develop a shear deformation causing considerable residual stress into a sheet metal. In this work, the incremental hole-drilling (IHD) method was applied to determine the through-thickness residual stress distribution. The ECAR was first carried out on a 2 mm Al 5083 sheet for three passes through the channels. The residual stress field was then evaluated using the IHD method. The calibration coefficients A n and B n were obtained by finite element method. It was observed that the residual stress profile through the material thickness was non-uniform and it changed from compressive at the top surface to tensile at the bottom surface in rolling direction. Also, the integral method as an alternative method of calculation was used to determine the residual stresses. There was a good agreement between the results of two calculation methods. It is shown the equal channel angular rolled sample can reveal a maximum residual stress of nearly 45% of its yield strength.