Split sleeve cold expansion (SSCE) is a crucial cost-effective process to improve the fatigue life of metallic structures with holes in the aerospace industry. In this study, the effects of the workpiece material’s yield strength (290.9 MPa to 377.8 MPa) and the applied SSCE expansion percentage (3.330% to 4.377%) on mandrel pulling force and residual stresses were investigated numerically for aluminum 2024-T351. A three-dimensional finite element (FE) model was developed to simulate the SSCE process using a commercial FE software, ABAQUS. The model geometries, material non-linearities, and contact conditions were adopted according to aerospace industrial applications’ standards. After the numerical model was validated with the published data, a parametric study with variable material properties and expansion percentage was conducted using the FE model. Our parametric study shows that an increase in both the Al workpiece’s yield strength and SSCE expansion percentage can improve the induced residual stresses in the hoop direction around the cold expanded hole; however, the workpiece’s yield strength has a higher impact on the residual stress field. The in-process pulling force during the SSCE process increases with increasing workpiece yield strength and expansion percentage.

对开套筒冷膨胀 (SSCE) 是提高航空航天工业中带孔金属结构疲劳寿命的关键成本效益工艺。在这项研究中，工件材料的屈服强度（290.9 MPa 至 377.8 MPa）和应用的 SSCE 膨胀百分比（3.330% 至 4.377%）对铝 2024-T351 的芯棒拉力和残余应力的影响进行了数值研究。开发了三维有限元 (FE) 模型以使用商业有限元软件 ABAQUS 模拟 SSCE 过程。根据航空航天工业应用标准采用模型几何形状、材料非线性和接触条件。数值模型经过公开数据验证后，使用有限元模型进行了具有可变材料特性和膨胀百分比的参数研究。我们的参数研究表明，Al 工件的屈服强度和 SSCE 膨胀百分比的增加可以改善冷扩孔周围环向的诱导残余应力；然而，工件的屈服强度对残余应力场的影响更大。SSCE 过程中的过程中拉力随着工件屈服强度和膨胀百分比的增加而增加。