Simulation of residual stress using thermomechanical analysis on wire EDM cut surface

2019 ◽  
Vol 19 ◽  
pp. 462-467 ◽  
Author(s):  
Sujay Bhattacharya ◽  
Abhishek Mishra ◽  
Tarvinder Singh ◽  
Srijit Bandyopadhyay ◽  
Santhosh Kumar ◽  
...  
Keyword(s):  
Residual Stress ◽  
Thermomechanical Analysis ◽  
Wire Edm ◽  
Cut Surface

scholarly journals Residual Stress Measurements on a Metal Matrix Composite Using the Contour Method with Brittle Fracture

2014 ◽  
Vol 996 ◽  
pp. 349-354 ◽  
Author(s):  
Jeferson Araujo de Oliveira ◽  
Michael E. Fitzpatrick ◽  
Jan Kowal
Keyword(s):  
Residual Stress ◽  
Fatigue Crack ◽  
Brittle Failure ◽  
Metal Matrix ◽  
Crack Surface ◽  
Contour Method ◽  
Wire Edm ◽  
Stress Measurements ◽  
Fatigue And Fracture ◽  
Cut Surface

In this work we evaluate the application of the contour method to fatigue and fracture surfaces. Residual stress measurements were made on quenched and aged AA2124-SiCp composite using neutron diffraction, the contour method with wire EDM, and the contour method on a fatigue crack surface including brittle failure. The contour method successfully measured residual stresses from a wire electro-discharge cut surface, but the fracture method results suggest that residual stress information is lost due to plasticity during fatigue crack growth.

scholarly journals Experimental study of the effects of wire EDM on the characteristics of ferritic steel, at a micro-scale on the contour cut surface

2018 ◽  
Vol 115 (4) ◽  
pp. 413
Author(s):  
Nida Naveed
Keyword(s):  
Residual Stress ◽  
Stress Measurement ◽  
Surface Characteristics ◽  
Surface Damage ◽  
Cutting Process ◽  
Contour Method ◽  
X Ray Diffraction ◽  
Micro Scale ◽  
Macro Scale ◽  
Cut Surface

This study, on a micro-scale, of the WEDM cut surfaces of specimens to which the contour method of residual stress measurement is being applied provides detailed information about the effects of the cutting process on the surface quality. This is defined by a combination of several parameters: variation in surface contour profile, sub-surface damage and surface texture. Measurements were taken at the start, the middle and at the end of the cut. This study shows that during WEDM cutting, a thin layer, extending to a depth of a few micrometres below the surface of the cut, is transformed. This layer is known as the recast layer. Using controlled-depth etching and X-ray diffraction, it is shown that this induces an additional tensile residual stress, parallel to the plane of the cut surface. The WEDM cut surface and sub-surface characteristics are also shown to vary along the length of the cut. Moreover, these micro-scale changes were compared with macro-scale residual stress results and provides an indication of the point at which the changes occurred by cutting process can be significantly relative to the macro-scale residual stress in a specimen.

scholarly journals Numerical Simulation of Cut Surface Shape and Residual Stress Distribution in Shearing Process

2019 ◽  
Vol 60 (9) ◽  
pp. 1996-2002
Author(s):  
Masaru Fukumura ◽  
Yoshiaki Zaizen ◽  
Takeshi Omura ◽  
Kunihiro Senda ◽  
Yoshihiko Oda
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Stress Distribution ◽  
Residual Stress Distribution ◽  
Surface Shape ◽  
Cut Surface

scholarly journals Numerical Simulation of Cut Surface Shape and Residual Stress Distribution in Shearing Process

2018 ◽  
Vol 59 (688) ◽  
pp. 65-70
Author(s):  
Masaru FUKUMURA ◽  
Yoshiaki ZAIZEN ◽  
Takeshi OMURA ◽  
Kunihiro SENDA ◽  
Yoshihiko ODA
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Stress Distribution ◽  
Residual Stress Distribution ◽  
Surface Shape ◽  
Cut Surface

scholarly journals Thermal and Residual Stress Distributions in Inconel 625 Butt-Welded Plates: Simulation and Experimental Validation

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Harinadh Vemanaboina ◽  
Edison Gundabattini ◽  
Kaushik Kumar ◽  
Paolo Ferro ◽  
B Sridhar Babu
Keyword(s):  
Residual Stress ◽  
Arc Welding ◽  
Thermomechanical Analysis ◽  
Numerical Code ◽  
Inconel 625 ◽  
Stress Distributions ◽  
X Ray Diffraction ◽  
Gas Tungsten Arc ◽  
Thermal Measurements ◽  
Gtaw Process

Thermal and residual stress distributions induced by the gas tungsten arc welding (GTAW) process on Inconel 625 were studied using numerical simulation and experiments. A multi-pass welding model was developed that uses a volumetric heat source. Thermomechanical analysis is carried out to assess the Thermal and residual stress distributions. Experiments were carried out with 5 mm thick Inconel 625 plates. X-ray diffraction techniques were used to measure residual stresses, and IR thermometry was employed to capture the temperature values on the welded joints. Simulations were performed with ANSYS numerical code, and a close agreement was found between the predicted and experimentally measured residual stress. Thermal measurements were collected pass by pass from the analysis, and the agreement was 9.08%. The agreement between the measured and analysed residual stress was 11%.

Laser Cutting of Small Diameter Holes Into Alumina Tiles: Thermal Stress Analysis

2011 ◽  
Vol 133 (2) ◽  
Author(s):  
B. S. Yilbas ◽  
S. S. Akhtar ◽  
C. Karatas
Keyword(s):  
Residual Stress ◽  
Laser Cutting ◽  
Small Diameter ◽  
Optical Microscope ◽  
Stress Fields ◽  
Finite Element Code ◽  
X Ray Diffraction ◽  
X Ray ◽  
Cut Surface ◽  
Scanning Electron

Laser cutting of small diameter holes in alumina tiles is carried out. Temperature and stress fields are predicted numerically using the ABAQUS finite element code. The cut sections are examined by incorporating scanning electron microscope and optical microscope. The residual stress developed in the cutting section is determined using the X-ray diffraction technique. It is found that high residual stresses are formed in the cutting section, and predictions agree well with the experimental results. The laser cut edges are found to be free from the large cracks. However, interconnected shallow cracks are observed at the hole cut surface.

Methods for Determination of Residual Stress of a Formed Plate Using Laser Ablation, Wire EDM and Milling

2011 ◽  
Vol 473 ◽  
pp. 368-375
Author(s):  
Janne Lämsä ◽  
Kari Mäntyjärvi ◽  
Antti Järvenpää ◽  
Martin Grüner ◽  
Marion Merklein ◽  
...  
Keyword(s):  
Residual Stress ◽  
Laser Ablation ◽  
Residual Stresses ◽  
Pulse Length ◽  
High Strength ◽  
Wire Edm ◽  
Air Bending ◽  
Speci Mens ◽  
Dimensional Errors

In this work laser ablation was used for the determination of residual stress of a formed plate. Manufacturing processes, like bending, create residual stresses in the product and those can be very disadvantageous for fatigue durability. Residual stresses that are generated during the manu-facturing of products can cause distortions, dimensional errors or can even break the products. The research material was ultra-high-strength steel (UHSS) with a yield strength of 1100 MPa. Speci-mens with a 90 degree bent angle were made by air bending using a press brake. Air bending causes variable residual stress patterns in the cross section of the material. The residual stresses of the formed area were determined by removing material and measuring strains caused by the release of stresses. A slot with the width of 1 mm has been manufactured parallel to the edge, both on the outer and on the inner side of the bend. True residual stress distribution can be calculated from the measured strains. A pumped 1064 nm Nd:YVO4 ablation laser, whose pulse length is 90 ns, was used for the removal of material. This process creates a negligible heat affected zone (HAZ) and laser ablation doesn’t increase stresses in the specimen. The results were compared with those ob-tained when slots were produced by milling and wire-EDM, as well as with the stress values meas-ured by X-ray diffraction.

Wire-EDM Properties of EC-PCD Made up of Boron Doped Diamond Particles

2014 ◽  
Vol 1017 ◽  
pp. 770-775 ◽  
Author(s):  
William Chen ◽  
Shinichi Ninomiya ◽  
Shunsuke Nochi ◽  
Manabu Iwai ◽  
Kiyoshi Suzuki
Keyword(s):  
Laser Scanning ◽  
Cutting Speed ◽  
Wire Edm ◽  
Boron Doped Diamond ◽  
Grain Sizes ◽  
The Past ◽  
Boron Doped ◽  
Diamond Particles ◽  
Cut Surface ◽  
Cutting Experiments

It has been made clear that the EC-PCD composed of boron doped diamond particles improves the performance in the die sinking EDM and wire EDM in comparison with the existing standard PCD (S-PCD). However, the effect of the property improvement could not been evaluated quantitatively in the research reports in the past. Therefore, in this study, wire EDM cutting tests were conducted on the specimens of S-PCD and EC-PCD, in addition to the evaluation of cutting efficiency and cutting PCD surface, a detailed investigation of the cut surface properties of the PCD has been performed under the color 3D laser scanning microscope. In order to investigate effects of a grain size of the source diamond, EDM cutting experiments were conducted on the EC-PCD specimens of 4 different grain sizes. As a result, it was found that the cutting speed was higher in the case of EC-PCD than the case of S-PCD, e.g., by 20% and 40% respectively in the sample of 10μm and 25μm particle size. Also, in the case of the cut S-PCD surface, a groove due to the discharge is formed in the boundary of the tungsten carbide layer and the PCD layer. However, in the case of the cut EC-PCD surface, the groove did not appear in the boundary.

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