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Optimization of Finite Element Mesh for Residual Stress Measurement Using Contour Method.

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Title: Optimization of Finite Element Mesh for Residual Stress Measurement Using Contour Method.
Authors: Luo, Z.1,2 (AUTHOR), Liu, C.1,2 (AUTHOR) chuanliu@fosu.edu.cn, Li, J.3 (AUTHOR), Li, X.1,2 (AUTHOR), Ji, X.1,2 (AUTHOR)
Source: Experimental Techniques. Jun2026, Vol. 50 Issue 3, p481-502. 22p.
Subjects: Finite element method, Numerical grid generation (Numerical analysis), Optimization algorithms, Residual stresses, Statistical reliability
Abstract: Stress reconstruction using finite element (FE) simulation is the critical step during residual stress measurement with contour method (CM). The quality of the FE mesh influences the accuracy of CM. There are no guidelines or suggestions to be referred to meshing the FE model for CM stress construction to improve the measurement accuracy. This study aims to distinguish the effects of FE mesh on the measurement accuracy with CM and give an optimal meshing scheme for the FE model of CM by balancing measurement accuracy and computation efficiency. A four-point bending beam was simulated to obtain the initial residual stress field. Then the CM measurement procedure was simulated with the pre-stressed bending beam model and the effects of FE mesh on the final constructed stress of CM were studied. Finally, the optimal meshing scheme in different regions of the bending beam was obtained. Results shows that the FE model employing the mapped mesh with the deformation measuring spacing in the cutting plane, mapped mesh with minimum sizes ranging from 0.01 mm to 0.09 mm in the direction normal to the cutting plane in the adjacent region of the cutting plane, and free mesh in the remaining 85% of the model length can reduce the root mean square stress by approximately 12% and control the relative error of peak stress within 4%. The proposed meshing scheme is applied to the CM stress constructions of an edge autogenously welded stainless steel beam, a multi-pass butt-welded high-strength steel plate, and a linear friction welded titanium alloy plate joint. It is found the peak stresses are underestimated with the conventional FE model. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:Stress reconstruction using finite element (FE) simulation is the critical step during residual stress measurement with contour method (CM). The quality of the FE mesh influences the accuracy of CM. There are no guidelines or suggestions to be referred to meshing the FE model for CM stress construction to improve the measurement accuracy. This study aims to distinguish the effects of FE mesh on the measurement accuracy with CM and give an optimal meshing scheme for the FE model of CM by balancing measurement accuracy and computation efficiency. A four-point bending beam was simulated to obtain the initial residual stress field. Then the CM measurement procedure was simulated with the pre-stressed bending beam model and the effects of FE mesh on the final constructed stress of CM were studied. Finally, the optimal meshing scheme in different regions of the bending beam was obtained. Results shows that the FE model employing the mapped mesh with the deformation measuring spacing in the cutting plane, mapped mesh with minimum sizes ranging from 0.01 mm to 0.09 mm in the direction normal to the cutting plane in the adjacent region of the cutting plane, and free mesh in the remaining 85% of the model length can reduce the root mean square stress by approximately 12% and control the relative error of peak stress within 4%. The proposed meshing scheme is applied to the CM stress constructions of an edge autogenously welded stainless steel beam, a multi-pass butt-welded high-strength steel plate, and a linear friction welded titanium alloy plate joint. It is found the peak stresses are underestimated with the conventional FE model. [ABSTRACT FROM AUTHOR]
ISSN:07328818
DOI:10.1007/s40799-025-00859-5