A thermo – Mechanical modelling approach on the residual stress prediction of SLM processed HPNGV aeroengine part

2021 ◽  
Author(s):  
BK. Nagesha ◽  
S. Anand Kumar ◽  
K. Vinodh ◽  
Akshay Pathania ◽  
Sanjay Barad
Keyword(s):  
Residual Stress ◽  
Mechanical Modelling ◽  
Stress Prediction ◽  
Modelling Approach

Multi-physics continuum modelling approaches for metal powder additive manufacturing: a review

2020 ◽  
Vol 26 (4) ◽  
pp. 737-764 ◽  
Author(s):  
Shekhar Srivastava ◽  
Rajiv Kumar Garg ◽  
Vishal S. Sharma ◽  
Noe Gaudencio Alba-Baena ◽  
Anish Sachdeva ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Powder Layer ◽  
Extensive Review ◽  
Content Type ◽  
Continuum Modelling ◽  
Mechanical Modelling ◽  
Mitigation Techniques ◽  
Am Processes ◽  
Modelling Approach

Purpose This paper aims to present a systematic approach in the literature survey related to metal additive manufacturing (AM) processes and its multi-physics continuum modelling approach for its better understanding. Design/methodology/approach A systematic review of the literature available in the area of continuum modelling practices adopted for the powder bed fusion (PBF) AM processes for the deposition of powder layer over the substrate along with quantification of residual stress and distortion. Discrete element method (DEM) and finite element method (FEM) approaches have been reviewed for the deposition of powder layer and thermo-mechanical modelling, respectively. Further, thermo-mechanical modelling adopted for the PBF AM process have been discussed in detail with its constituents. Finally, on the basis of prediction through thermo-mechanical models and experimental validation, distortion mitigation/minimisation techniques applied in PBF AM processes have been reviewed to provide a future direction in the field. Findings The findings of this paper are the future directions for the implementation and modification of the continuum modelling approaches applied to PBF AM processes. On the basis of the extensive review in the domain, gaps are recommended for future work for the betterment of modelling approach. Research limitations/implications This paper is limited to review only the modelling approach adopted by the PBF AM processes, i.e. modelling techniques (DEM approach) used for the deposition of powder layer and macro-models at process scale for the prediction of residual stress and distortion in the component. Modelling of microstructure and grain growth has not been included in this paper. Originality/value This paper presents an extensive review of the FEM approach adopted for the prediction of residual stress and distortion in the PBF AM processes which sets the platform for the development of distortion mitigation techniques. An extensive review of distortion mitigation techniques has been presented in the last section of the paper, which has not been reviewed yet.

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.

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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