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*Corresponding author (email: xiehm@mail.tsinghua.edu.cn)
SCIENCE CHINA
Physics, Mechanics & Astronomy


Article

Study of the Location of Testing Area in Residual Stress Measurement by Moir Interferometry Combined With
Hole-drilling Method
QIN Le
1
, XIE HuiMin
1*
, ZHU Ronghua
1
, WU Dan
1
, CHE Zhigang
2
, ZOU Shikun
2

Sci China-Phys Mech Astron, Just Accepted Manuscript DOI: 10.1007/s11433-013-5256-5 Publication
Date (Web): 30 Jan 2013

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Study of the Location of Testing Area in Residual Stress Measurement
by Moir Interferometry Combined With Hole-drilling Method
QIN Le
1
, XIE HuiMin
1*
, ZHU Ronghua
1
, WU Dan
1
, CHE Zhigang
2
, ZOU Shikun
2
1
AML, Department of Engineering Mechanics, Tsinghua University, Beijing 100084, China
2
Beijing Aeronautical Manufacturing Technology Research Institute, Beijing 100024, China
*Corresponding author: xiehm@mail.tsinghua.edu.cn

This paper investigates the effect of the location of testing area in residual stress measurement by Moir interferometry
combined with hole-drilling method. The selection of the location of the testing area is analyzed from theory and experiment.
In the theoretical study, the factors which affect the surface released radial strain
r
were analyzed on the basis of the formulae
of the hole-drilling method, and the relations between those factors and
r
were established. By combining Moir
interferometry with the hole-drilling method, the residual stress of interference-fit specimen was measured to verify the
theoretical analysis. According to the analysis results, the testing area for minimizing the error of strain measurement is
determined. Moreover, if the orientation of the maximum principal stress is known, the value of strain will be measured with
higher precision by the Moir interferometry method.
hole-drilling, residual stress, Moir interferometry, testing area
PACS: 42.30.Ms, 62.20.Fe, 06.20.Dk





1 Introduction
Moir interferometry combined with hole-drilling is an effective method for residual stress measurement, which
was born in the 1930s [1], and has developed into a mature experimental methods for measuring residual stress.
According to this method, a small hole is drilled on the specimen, and then the deformation of the surrounding
surface is measured to evaluate the local residual stresses. The common criterion for hole-drilling method is
ASTM E837-08 standard [2] of the United States, which uses strain gauges to measure the surface strain. It is
generally known that the released strain around the small hole after drilling has a large attenuation gradient, so the
use of strain gauges for the measurement creates problems. Firstly, the residual stress decreases rapidly along the
radius while the measuring points of the strain gauges are away from the hole boundaries, which make the sensor
less sensitive. Secondly, the result is the average strain in the gage length, and in case of high stress gradient, the
measurement contains a high probability of error. In addition, fewer measuring points utilized in the strain gauge
measurement may result in large random error.
At the same time, additional stress will inevitably be produced in the drilling process, which even results in plastic
deformation around the hole [3-8]. A relative large error will occur if the strain close to the edge of the hole is
used to calculate the released stress. So the key point to reduce the experimental error is to select the appropriate
location around the hole for the strain measurement.
In this paper, the location of the testing area in the measurement by hole-drilling method has been analyzed from
both theory and experiment. In the theoretical analysis part, based on the theoretical formula of the hole-drilling
method, the factors that affect the released radial strain
r
around the hole have been studied. In the experimental
analysis part, the residual stress of interference-fit specimen which has the theoretical solution has been measured
by Moir interferometry method to validate the theoretical solutions [9-14]. At last, the location of testing area in

the measurement to minimize errors has been determined.
2 Theory research on the location of strain measurement
In order to reduce the strain measurement error, the location of higher released strain after drilling is necessary to
be determined through theory. As to the relation between
r

and
1
,
2
, , analytical solution can be obtained only
in the through hole condition, while in the blind hole condition, there are no theoretical solutions. Because the
trend of
r
is similar in different conditions, it is proper to study the impact of r/a,

on the measurement error
using through hole solution in theory.
In the case of through hole, the theoretical solution to the released radial strain
r

around the hole can be expressed
as [15]:
( ) ( )
1 2 1 2
cos 2
r
A B c o o o o u = + + (1)
( )
2
2
4 2
4 2
1
2
1 4
3 1
2
a
A
E r
a a
B
E r r
u
u
+
=

= +
(

in which
r

is the released radial strain, A and B are related parameters, which can be obtained by finite element
analysis or experiment methods, E is the Youngs modulus,
1
and
2

are maximum and minimum principal
stresses respectively,

is the Poissons ratio, a is the radius of hole, r

is the distance between the strain
measurement location and the hole center, and is the angle between
r

and
1
.
Let
0
r
r
c c
=
c
(2)
Then
2 1 2
1 2 1 2
6(1 )( ) cos 2
( )
(1 )( ) 4( ) cos 2
r
a
v o o u
v o o o o u
+ +
=
+ + +
(3)
From Equation (1), it can be seen that the value of
r
is very small when r

is too large. It may bring relative large
error if the location of the testing area far away from the hole is chosen for the measurement, so an appropriate r
with a larger
r
is important in strain measurement. Equations (2) to (3) show that whether
r
has the maximum
value is associated with , ,
1
,
2
.
2.1 Uniaxial stress condition
A modified hole-drilling procedure is used to measure residual stresses in thin plate and sheet materials in
[16].The recommended location of testing area under uniaxial stress condition has been investigated. When the
specimen is under uniaxial stress condition, according to equation (1) and the idea from Ref. [16], in which
E=200GPa, =0.3,
1
=300MPa,
2
=0 is assumed. The relation between
r
and r/a, can be gotten, as shown in
Figure 1.



Figure 1 Relation diagram of
r
, r/a,

under uniaxial stress condition (
1
=300MPa,
2
=0)
Figure 1 shows that released radial strain
r
reaches a maximum when 1<r/a<1.8 under uniaxial stress condition.
However, a certain degree of plastic deformation occurs around the edge of the hole during the hole-drilling. The
influence scope is about 1<r/a<1.1, so it is suitable to take 1.1<r/a<1.8 in the measurement of residual stress
under uniaxial stress condition. For the same r/a,
r
has the maximum when =0, which leads to the smallest
relative error in strain measurement.
2.2 Biaxial stress condition
When the specimen is under biaxial stress condition, according to equation (1), in which E=200GPa, =0.3 is
assumed, the relation between
r
and r/a, ,
1
/
2
can be gotten respectively, as shown in Figure 2-3.


Figure 2(a) Figure 2(b)



Figure 2(c) Figure 3
Figure 2 (a) Relation diagram between
r
and r/a, under a biaxial tensile stress (
1
=100MPa,
2
=300MPa). (b) Relation diagram between
r
and
r/a,

under a biaxial compress stress (
1
=-100MPa,
2
=-300MPa). (c) Relation diagram between
r
and r/a, under a pure shear stress (
1
=100MPa,

2
=-100MPa).
Figure 3 Relation diagram between
r
and r/a,
1
/
2
under a biaxial stress (=0)
Figure 2 shows the relation between
r
and r/a, under three different stress conditions. It indicates
r
gets a larger
value when 1.2<r/a<1.6 under biaxial stress condition, which helps minimize measurement errors. For the same
r/a, the influence of on
r
is the same as that under uniaxial stress condition.
Figure 3 shows the relation between
r
and r/a,
1
/
2
under a biaxial stress. Under biaxial stress condition,
r
has
the maximum when 1.1<r/a<2.5 for
1
/
2
with different values. The value of
r
changed slightly when 1.1<r/a<1.6,
so 1.1<r/a<1.6 is a reasonable scope for the strain measurement.
3 Experimental study of the location of strain measurement
3.1 Production of interference-fit specimen
In order to study the influence of strain measurement location on residual stress measurement, a pure aluminum
interference-fit specimen was produced. The outer and inside diameters of the hub are 128mm and 64mm
respectively and the shaft diameter is 64.1mm. Hub and shaft have the same thickness, 10mm. In the
manufacturing process, the hub should be heated to 120 firstly, and it is necessary to maintain appropriate
temperature to prevent changing the structure of hub. Then, the shaft should be cooled by NO
2
(-70) or
compressed air (-190). At last, the shaft is mounted into the hub before the specimens are brought to room
temperature. The structures are shown in Figure 4 and the specific parameters are shown in Table 1.

Figure 4 Schematic diagram of aluminum interference-fit specimen (Unit: mm)

Table 1 Parameters of the interference-fit specimen size
Parameter Value
Hub outer diameter
1
128mm
Hub inside diameter
2
64mm
Shaft diameter
3
64.1mm
Interference fit tolerance 0.1mm
Hub thickness h
1
10mm
Shaft thickness h
2
10mm
Young's modulus E 70GPa


Poisson's ratio 0.33
For the interference-fit specimen produced by the method described above, the residual stress of the hub has the
analytical solution [17-18]. Figure 5 shows the theoretical solution of stress distribution in the hub.

Figure 5 Hub stress distribution of analytical solution and finite element analysis (
r
, F
r
is the analytical solution and numerical solution to radial
stress respectively.

, F

is the analytical solution and numerical solution to circumferential stress respectively. r is the distance to the center of the
shaft.)
3.2 Residual stress measurement by Moir interferometry
The location close to the inner hub is selected during the residual stress measurement, in which the level of
residual stress is relatively high. The gratings are transferred on the surface of hub before drilling. Figure 6 shows
the specimen after drilling. The holes are drilled along the circle with a radius of L and the holes spacing distance
meets the ASTM E837-08 standard. The dimensions and theoretical solutions to residual stresses of the holes are
shown in Table 5.

Figure 6 Schematic diagram of the distribution of drilling point

Table 2 Theoretical solutions to residual stresses of the holes
Hole
No.
Aperture
d
(mm)
Hole
depth h
(mm)
Center
distance L
(mm)

r

(MPa)

(MPa)
1 2 2.5 34 -32.6 58.2
2 2 2.5 34 -32.6 58.2
3 1 1.5 34 -32.6 58.2
4 1 1.5 34 -32.6 58.2

5 1 1.5 34 -32.6 58.2

In the condition of deep blind hole (h>1.2d), the released stress through further drilling has little impact on the
surface radial strain, so equation (1) can also apply to deep blind hole condition. As shown in equation (1), the
related parameters A, B can be calibrated by two specific conditions of loading. A can be gotten under a biaxial
equal stress condition (
1
=
2
=). B can be determined under a pure shear stress condition (
1
=-
2
=).
( , , , )
2
( , , , )
2 cos 2
r
r
A E a r
B E a r
c
v
o
c
v
o u

(4)
in which
r
can be gotten by finite element analysis. A, B depend only on E, , a and r, and the graph of the values
of A, B results are shown in Figure 7.


Figure 7 Finite element analysis calibration values of A, B of deep blind hole of aluminum specimen

3.2.1 Principle of Moir interferometry
Moir interferometry is a full-field optical method for the measurement of in-plane displacement fields. The
principle is shown in Figure 8. A grating with a frequency of 1200 lines/mm is bonded directly to the surface of
the specimen and carries the deformation of the specimen. The sensitivity of Moir interferometry to displacement
measurement is the half of the grating pitch, which can reach sub-micrometer level.
Before deformation, the mutual interference of two diffracted beams produces a uniform light intensity throughout
the field. When the specimen deforms, the specimen grating deforms accordingly at the same time, resulting in
warped wave fronts M and N. The resulting interference patterns represent contours of displacement. According
to the wave front interferometry theory, the two incident angles of the beams should satisfy:
arcsin( ) f o = (5)




Figure 8 Schematic diagram of principle of Moir interferometry
The 2D in-plane displacement U and V

can be obtained from the fringe order N
x
and N
y
by [19-20]
2
x
N
f
U = ,
2
y
N
f
V = (6)
and the in-plane strain by
1 1
2 2
1 1
2 2
1
( )
2
x x
x
y y
y
y
x
xy
N N U
x f x f x
N N
V
y f y f y
N
N U V
y x f y x
c
c

c A c
= = ~
c c A
c A
c
= = ~
c c A
A
A c c
= + ~ +
c c A A
(7)
where =632.8nm is the wavelength of He-Ne gas laser and f=1200lines/mm is the frequency of the specimen
grating used in the test.

3.2.2 Fringe processing using phase-shifting method
The phase-shifting method [21] is one of the most efficient fringe processing methods. In contrast to the fringe
center method [22] based on intensity analysis of fringes, this method can directly obtain the phase through a
series of interference fringe images, and then accurately determine displacement and strain fields [14].
In this experiment, a PZT driver is used to produce phase shifts to generate four sequential images with an
equal phase shift. This phase distribution can be calculated from the four images using the Carr algorithm [23].
| | | |
1 4 2 3 2 3 1 4
2 3 1 4
( ) ( ) 3( ) ( )
arctan
( ) ( )
I I I I I I I I
I I I I
|
+
=

+ +
(8)
in which | is the phase and
1 2 3 4
, , , I I I I are the corresponding intensities of the four images respectively.

3.2.3 Experimental procedure and results
The hole-drilling method could be divided into three steps ordinarily. Firstly, the test area of specimen is polished
and then the gratings with a frequency of 1200 lines/mm are transferred on it [20, 24]. Secondly, several holes are
drilled perpendicular to the plate surface. The deformation incurred by the released residual stress will be recorded
on the specimen grating. In this process, it is significant to ensure that the gratings are not damaged during drilling
holes: (1) a flexible drilling device with a small electric motor is designed and used, as shown in Figure 9; (2) an
appropriate drilling speed of 7200 r/min is chosen, matched with the hardness of the specimen; (3) distilled water

is kept dropping on the surface of gratings, preventing excessive temperature on the surface. Finally, the specimen
with gratings is put into the Moir interferometer, capturing the Moir patterns.

Figure 9 Schematic diagram of the hole-drilling device(1- holding device; 2- drilling device; 3- stepping motor controller)

After the Moir interferometer is aligned to get a null-field Moir pattern, the deformed specimen grating is then
placed in the Moir interferometer to generate Moir patterns which represents the residual deformation. The
phase shifting method is applied for the automatic process of the Moir fringes. In the measurement, the four-step
phase-shifting algorithm is utilized to analyze the Moir images. Figure 10 shows U and V Moir patterns of holes.
PZT driver is applied to produce phase shifts generating four sequential images with an equal phase shift and the
phase of each condition in the map was 0, /2, and 3/2.





Figure 10 U and V Moir patterns of Holes 1 to 5 without any processing (The hole size is shown in Table 2; U and V directions are perpendicular
to and along the radius of interference-fit specimen respectively): (a) U

field Moir pattern of Hole 1; (a) V field Moir pattern of Hole 1; (b) U

field
Moir pattern of Hole 2; (b) V field Moir pattern of Hole 2; (c) U

field Moir pattern of Hole 3; (c) V field Moir pattern of Hole 3; (d) U

field
Moir pattern of Hole 4; (d) V field Moir pattern of Hole 4; (e) U

field Moir pattern of Hole 5; (e) V field Moir pattern of Hole 5



Figure 11 U

and V field maps of Holes 1 to 5 (unit: mm): (a) U displacement field of Hole 1; (b) U displacement field of Hole 2; (c) U

displacement field of Hole 3; (a) V displacement field of Hole 1; (b) V displacement field of Hole 2; (c) V displacement field of Hole 3; (d) U
displacement field of Hole 4; (e) U displacement field of Hole 5; (d) V displacement field of Hole 4; (e) V displacement field of Hole 5

Figure 11 is the distribution maps of U and V displacement field, we can see that the released displacements by
hole-drilling are highly concentrated around the holes, while decreasing rapidly far away from the center of hole.
The released displacement is mainly concentrated within 3r
0
.
As shown in Figure 12, the experimental values of

and
r
have the minimum relative errors when 1.2<r/a<1.4
and have larger relative errors when 1< r/a<1.2. This may be caused by the plastic deformation taking place
around the hole in the course of drilling. When r/a>2, the measured values are much higher than theoretical values,
that is because with the increase of r value, the decay speed of
r
is slower than that of related parameters A and B.



Figure 12 (a) Relation between the experimental values of

and r/a. (b) Relation between the experimental values of
r
and r/a

In order to study the influence of

on the strain measurement result, the circle r/a=1.5

is selected. In the circle
r/a=1.5, six points with different , which are -15, 10, 30, 50, 62.5 and 70, are determined to measure
residual stress. As analyzed in Table 2, the theoretical values of

and
r
are respectively 58.2MPa and -32.6MPa.
The experimental values of residual stresses are shown in Fig.13. The smaller is, the error is lower.

Figure 13 (a) Relation between the experimental values of

and when r/a=1.5
(b) Relation between the experimental values of
r
and when r/a=1.5
4 Conclusions
In this paper, the range of radial strain value in hole-drilling method is studied in combination with theoretical
analysis and experiment. The testing area for minimizing the error of strain measurement is determined. Specific
findings can be summarized below.
(1) The relation between
r
and r/a, ,
1
/
2
is studied theoretically. The proper range of r/a and

for residual
stress measurement is gotten in which
r

reaches its extremum and has the smallest error. Then, the
residual stress of the interference-fit specimen is measured through Moir interferometry, verifying the
theoretical analysis.
(2) Theoretical study shows that in plane stress state,
r

reaches a maximum when 1.2<r/a<1.6. To the same
r/a, the smaller

is, the bigger
r
. The experimental results show that

and
r

of interference-fit
specimen produce the smallest errors when 1.2<r/a<1.6, and the smaller

is, the smaller the error of
strain in the measurement.
(3) In the residual stress measurement of actual engineering component, because of the uncertainty of the
residual stress distribution, its main stress direction is unknown, so it is more important to determine
appropriate r/a. But when the principal stress orientation of the residual stress is known, it is necessary
to adjust

to a minimum in the measurement.

The results from this study may be helpful for determining the measurement location in the residual stress
measurement.


Acknowledgments

The authors are grateful to the financial support by the National Basic Research Program of China (973 Project)
(Grant No.2010CB631005, 2011CB606105), the National Natural Science Foundation of China (Grant Nos.
11232008, 91216301, 11227801, 11172151), and Tsinghua University Initiative Scientific Research Program.


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