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Residual Stress and Fatigue Strength of Cold-Rolled Carbon Steel
Residual Stress and Fatigue Strength of Cold-Rolled Carbon Steel
By Masahiko Ogirima*
To obtain the effect of cold rolling on fatigue strength, commercial 0.8% carbon eutectoid steel was cold-
rolled to various degrees of reduction and then fatigued in bending at constant deflection. On the other hand,
cold-rolled strips are always accompanied by residual stress, and the fatigue strength is much influenced by the
residual stress on the surface of cold-rolled sheets. The residual stress on the surface of the sheet cold-rolled at
each rolling rate was measured by the X-ray method (sin2ψ method) which was corrected by Fourie Analysis.
The intrinsic change of fatigue strength by cold rolling was obtained using the relation between fatigue strength
and mean bias stress. As a result, the fatigue strength increases monotonously with the reduction rate, and the
increasing rate of fatigue strength with the reduction rate in the earlier stage of cold rolling, if uncorrected by
residual stress, is very large because of the large compressive residual stress.
As an example, the residual stress on the surface of a cold-rolled sheet changes neither by the cold rolling
rate of at least more than 10% nor by the one-pass reduction in the range of 1.9%∼4.7%.
Commercial eutectoid steel SK5 (standard chemical and vice versa. Moreover, when v/1+v=sin2ψ dψ is
composition) was used. The cold-rolling process is equal to d⊥ without regard to the value of stress, then
indicated in Fig. 1. Table 1 shows the thickness, the group of those straight lines cross at only one
reduction rate, number of passes, and mean reduction point dψ=d⊥, sin2ψ=v/1+v.
rate per pass. In this experiment, the measurement was carried
Annealing was carried out at 750℃ for 1 hr in vacuo, out using a diffractonieter. The condition of
with attention to decarburization. Test pieces for diffraction is shown in Table 2. Usually, the diffrac-
fatigue and tensile tests were cut parallel to the tion pattern of the heavily-deformed crystal is very
rolling direction into the forms indicated in Fig. 2. broad. Therefore, in order to determine a correct
Since their fatigue characteristics is very sensitive to diffraction angle, the pattern was approximated to a
surface defects such as flaws and rusts, the test pieces parabola and the correct diffraction angle was gained
were handled with much caution and preserved in oil. by means of the least squares method.
A rectangular sheets (30×50mm) for X-ray The diffraction pattern from the heavily-deformed
measurement of residual stress was cut from No.1∼ crystal is very broad and the peaks by Kα, and Kα2
No.10 strips. For the purpose of comparing the overlap with each other, so the separation of these two
* Central Research Laboratory , Hitachi Ltd., Kokubunji, (1) A. L. Christenson and E. S. Rowland: Trans. ASM,
Tokyo, Japan. 45 (1953), 638.
Table 1 Reduction rate and one-pass reduction rate Table 2 Condition of diffraction
θΨ is the diffraction angle when the incident beam is 2. Fatigue strength and metallography
inclincd by ψ. The calculation was carried out using
a diffraction pattern by Kα
1 (curve B in Fig.3). Each
Fig. 5 shows S-N curves of specimensNo. 1, No. 2,
point in Fig. 4 is an average value of four specimens, No. 5 and No. 9 as representative examples. The
and the divergence is very small. Calculated values deviation of the plotting points is very small. As
of residual stress for specimens No.1∼No.10 are indi- indicated in Fig. 5, the inclined parts of S-N curves
Gated in Table 3. The residual stresses of specimens are always parallel in this case, suggesting that the
No.2∼No.10 are always compressive and almost the slope of the inclined part of the S-N curve is depend-
same value. If more accurate values are required, the ent not on the reduction rate but on the other factors
lattice plane dependence, absorption factor and such as the chemicalcomposition and heat treatment.
Lorentz polarization factor are necessary to be taken Fatigue limits obtained from each S-N curve are
into account, but in this experiment these corrections plotted against the cold reduction percentage in Fig.
were neglected. Moreover, it must be noted that the 6, which shows that the fatigue limits increase
values indicated in Table 3 is not the accurate values monotonously with the cold reduction percentage.
of stress on the surface, but the mean values of stress The variation of fatigue strength at the life of 105
of several microns under the surface. Then the cycles has the same tendency as that of fatigue limits.
correct absolute value on the surface is assumed to be The outline of the fracture surface of SK5 was much
a little larger than the gained values. jugged in contrast with that of 18-8 stainless steel.
An incubation period from the initiation of macro- the relations of these factors are assumed to be in-
scopic cracks to the final fracture (so-called3rd period dicated schematically in Fig. 9. Point P is thought
of fatigue) was long and at the time of fracture, to be decided by the nature of material and P shifts
many macroscopiccracks -werevisible on the specimen to the right side in the case,of softer* material and to
surface. the left in the case of harder* material. For the
Optical micrographs of specimens No. 1 and No. 9 purpose of comparing the. residual stress of SK5 with
are shown in Photo. 1(a) and (b). Photo. 1(a) is a that of othermaterialwhichhas largerdeformability,
usual pearlite structure and in (b) most layers of the residualstressof 18Cr-8Nistainlesssteel (30%
cementite were deformed to pieces. Nonmetallic in- cold-rolled)was measuredby the same methodas
clusions are very few. mentionedabove. And the result is 34.5kg/mm2
V. Discussion
1. Cold rolling and residual stress
As a matter of course, residual stress in a full-
annealed material is almost zero. When this material
is cold-rolled, the residual stress arises in it. The
characteristicsand the value of residual stress is said to
be dependent on the kind of a material and the method
of rolling. Fig. 7 and Fig. 8 show the dependenceof
residual stress on the reduction rate and the mean
reduction rate per one pass, respectively. These
figures show that in SK5, the residual stress on the
specimen surface is almost equal in the range 9.1∼
(tensile). In the case of cold rolling of 18-8 stainless the minimum value indicated, of course, the intrinsic
steel, the influence of martensitic transformation in fatigue strength when the residual stress does not
the course of cold rolling must be taken into consider- decrease at all. According to Fig. 10, the intrinsic
ation. fatigue strength increases monotonously by cold
rolling, but the change of fatigue strength in the range
2. Fatigue strength and residual stress of small cold reduction rates is larger in Fig. 6 because
Fig. 6 does not indicate the intrinsic relation of the effect of residual stress. Fatigue strength (both
fatigue limit and fatigue life) increases by cold rolling.
between fatigue strength and cold rolling rate, because
The fatigue limits of 90% cold-rolled specimen reaches
the effect of residual stress due to cold rolling is
about 1.5 times of full-annealed one. This increase
included in the fatigue strength obtained by the
is thought to be due to the high dislocation density,
usual testing method. The effect of residual stress
on fatigue strength has been studied by many research- formation of fibre structures and deformation of
ers, but the established theory about the relation pearlite structures (Photo. 1 (b)). The variation of
between residual stress and fatigue strength has never fatigue strength indicated in Fig. 10 includes all these
factors. In this experiment, these factors could not
been proposed. Then, the residual stress is assumed
to be regarded as mean bias stress and from the be separated but the increase of dislocation density is
considered to be a predominant factor. Fukui et al. (10)
experimental results of Sires(3), fatigue strength σω
can be related with mean bias stress σb (in this case σb
indicated that in 0.22% carbon steel, the fatigue limits
is equal to residual stress) as in the following formula: decreased once after small torsional deformation
(about several pct) was applied and increased by
(1) larger deformation.
In order to know the effect of the individual factors,
where σy is the yield stress and σ ω0 is the fatigue
microscopic investigations using a simpler material
strength when σb=0. The numerical coefficient 0.5
is expected.
is almost constant without regard to the kind of
material. The yield strength of each specimen was
obtained from stress-strain curves of tensile tests.
According to the formula (1), correction of Fig. 6 was
carried out and the result is indicated in Fig. 10.
Here, the variation of residual stress during the fatigue
test must be taken into consideration. These problems
have been studied mainly by Taira et al.(4)∼(9), and