A three dimensional elastic-plastic finite element investigation of elastic stress concentration factors and residual stress at radial cross-bores in thick cylinders under cyclic loading is presented. The effect of the ratio of internal blend corner to cross-bore radius on residual stress upon unloading is considered for a range of geometries. THe results presented indicate that the elastic stress concentration factor is relatively insensitive to corner radius, however the corner radius is significant when post-yield behaviour is considered. It is therefore concluded that corner radius and post-yield behaviour should be considered when calculating autofrettage pressures for cylinders with cross-bores.
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