The determination of residual stress in extruded Ti-6Al-4V by contour method and finite element analysis

J.D. Pollard, S. Rahimi, A. Watford, M. Jackson, B.P. Wynne

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

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The contour method has been used to assess the level of residual stress generated during the post extrusion air cool and water quenching of a Ti-6Al-4V extruded bar. A length of the extrudate was transversally sectioned using electrical discharge machining (EDM), resulting in minimal damage to the cut surface; the stress relieved profile present at the cut surface was then measured using a coordinate measuring machine (CMM). The cut section was recreated in an ABAQUS finite element (FE) model and the inverse of the stress relieved profile recorded by CMM was applied as a boundary condition; by forcing the model’s surface topology to match the measured cut surface, residual stresses normal, i.e. longitudinal stresses, to the cut surface of the extruded profile were then calculated. Results were compared to air cooling and quenching simulations performed in the DEFORM FE package. The distribution of tensile and compressive residual stresses observed via experimental and simulation work were found to be a good match with the distribution correlating with local variations of cooling rate during quenching.
Original languageEnglish
Title of host publicationProceedings of the 13th World Conference on Titanium
EditorsVasisht Venkatesh, Adam L. Pilchak, John E. Allison, Sreeramamurthy Ankem, Rodney Boyer, Julie Christodoulou, Hamish L. Fraser, M. Ashraf Imam, Yoji Kosaka, Henry J. Rack, Amit Chatterjee, Andy Woodfield
Place of PublicationHoboken, New Jersey
Number of pages6
Publication statusPublished - 6 May 2016
EventTi-2015: The 13th World Conference on Titanium - California, San Diego, United States
Duration: 16 Aug 201520 Aug 2015


ConferenceTi-2015: The 13th World Conference on Titanium
Country/TerritoryUnited States
CitySan Diego


  • extrusion
  • contour method
  • residual stress
  • Ti-6Al-4V
  • FEM


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