Residual Stress Prediction in the Casting Process of Automotive Powertrain Components

2021 ◽  
pp. 858-864
Author(s):  
S. Kianfar ◽  
J. Stroh ◽  
N. Bahramian ◽  
D. Sediako ◽  
A. Lombardi ◽  
...  
Keyword(s):  
Residual Stress ◽  
Casting Process ◽  
Stress Prediction ◽  
Automotive Powertrain

Development of a Residual Stress Simulation Benchmark for a Single Bead-on-Plate Weldment

2006 ◽  
Author(s):  
Peter J. Bouchard ◽  
Lyndon Edwards ◽  
Anastasius G. Youtsos ◽  
Roger Dennis
Keyword(s):  
Residual Stress ◽  
Assessment Procedure ◽  
Defect Assessment ◽  
Best Estimate ◽  
Weld Residual Stress ◽  
Single Bead ◽  
Stress Prediction ◽  
Stainless Steel Bead ◽  
Stress Simulation ◽  
Network Project

Finite element weld residual stress modelling procedures involve complex non-linear analyses where many assumptions and approximations have to be made by the analyst. Weld modelling guidelines for inclusion in the R6 defect assessment procedure are in preparation and will be accompanied by a series of validation benchmarks that can be used to evaluate the accuracy of weld modelling procedures and assess their suitability for use in fracture assessments. It is intended to base one of the benchmarks on a stainless steel bead-on-plate weldment that has been extensively studied by members of Task Group 1 of the NeT European Network project. This paper uses round robin residual stress measurements from the NeT project to derive a statistically based ‘best estimate’ distribution of transverse stress passing through the wall-section at mid-length of the bead-on-plate weldment. The accuracy of a state-of-the-art residual stress prediction is benchmarked against the best estimate measurements using a root mean square error analysis and comparisons of decomposed components of stress. The appropriateness of using the predicted residual stresses in fracture assessments is assessed by comparing stress intensity factors based on the measured and predicted distributions of stress. The results from these studies will be used to help establish accuracy targets and acceptance criteria for the welding benchmark.

About Residual Stress State of Castings: The Case of HPDC Parts and Possible Advantages through Semi-Solid Processes

2022 ◽  
Vol 327 ◽  
pp. 272-278
Author(s):  
Elisa Fracchia ◽  
Federico Simone Gobber ◽  
Claudio Mus ◽  
Yuji Kobayashi ◽  
Mario Rosso
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Casting Process ◽  
Ray Method ◽  
Premature Failure ◽  
Thin Walls ◽  
Residual Stress State ◽  
Semi Solid ◽  
Pressure Die Casting

Nowadays, one of the most crucial focus in the aluminium-foundry sector is the production of high-quality castings. Mainly, High-Pressure Die Casting (HPDC) is broadly adopted, since by this process is possible to realize aluminium castings with thin walls and high specific mechanical properties. On the other hand, this casting process may cause tensile states into the castings, namely residual stresses. Residual stresses may strongly affect the life of the product causing premature failure of the casting. Various methods can assess these tensile states, but the non-destructive X-Ray method is the most commonly adopted. Namely, in this work, the residual stress analysis has been performed through Sinto-Pulstec μ-X360s. Detailed measurements have been done on powertrain components realized in aluminium alloy EN AC 46000 through HPDC processes to understand and prevent dangerous residual stress state into the aluminium castings. Furthermore, a comparison with stresses induced by Rheocasting processes is underway. In fact, it is well known that Semi-Solid metal forming combines the advantages of casting and forging, solving safety and environmental problems and possibly even the residual stress state can be positively affected.

Two Case Studies in 3-D Residual Stress Prediction for Nuclear Power Applications

2016 ◽  
Author(s):  
Michael L. Benson ◽  
Patrick A. C. Raynaud ◽  
Frederick W. Brust
Keyword(s):  
Residual Stress ◽  
Nuclear Power ◽  
Three Dimensional ◽  
Repair Process ◽  
Three Dimensional Modeling ◽  
Dimensional Modeling ◽  
Weld Residual Stress ◽  
Plant Operations ◽  
Stress Prediction ◽  
Residual Stress Modeling

Residual stress prediction contributes to nuclear safety by enabling engineering estimates of component service lifetimes. Subcritical crack growth mechanisms, in particular, require residual stress assumptions in order to accurately model the degradation phenomena. In many cases encountered in nuclear power plant operations, the component geometry permits two-dimensional (i.e., axisymmetric) modeling. Two recent examples, however, required three-dimensional modeling for a complete understanding of the weld residual stress distribution in the component. This paper describes three-dimensional weld residual stress modeling for two cases: (1) branch connection welds off reactor coolant loop piping and (2) a mockup to demonstrate the effectiveness of the excavate and weld repair process.

3D Model of Shot Dynamics for Ultrasonic Shot Peening

2013 ◽  
Vol 768-769 ◽  
pp. 503-509 ◽  
Author(s):  
Jawad Badreddine ◽  
Emmanuelle Rouhaud ◽  
Matthieu Micoulaut ◽  
Sebastien Remy ◽  
Vincent Desfontaine ◽  
...  
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Spatial Data ◽  
Shot Peening ◽  
3D Model ◽  
Prediction Models ◽  
Dissipated Energy ◽  
Displacement Fields ◽  
Ultrasonic Shot Peening ◽  
Stress Prediction

This paper presents a 3D model that simulates an ultrasonic shot peening (USP) operation, using realistic process parameters and peening setups (part and chamber geometries). By simulating the shot dynamics (shot trajectories and impacts), statistical and spatial data are obtained for the peened component, i.e. surface coverage and coverage rate, impact speeds and angles, dissipated energy... This data can then be used for i) optimizing the design of peening chambers and process parameters and ii) predicting the residual stress and displacement fields induced by USP in the peened component. In fact, data from the 3D model can be used as initial data in existing residual stress prediction models. A chaining methodology was developed for this purpose and allows linking the choice of process parameters and USP setup to the induced residual stress displacement fields.

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