scholarly journals Residual Stresses Distributions in Grinding of 3J33 Maraging Steel with Miniature Electroplated CBN Wheel

2019 ◽  
Vol 256 ◽  
pp. 01002 ◽  
Author(s):  
Shouguo Shen ◽  
Beizhi Li ◽  
Weicheng Guo
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Maraging Steel ◽  
Ground Surface ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Compressive Stresses ◽  
Grinding Speed ◽  
Grinding Conditions

It is well known that the residual stresses on the ground surface and the subsurface can influence the service quality of a component, such as fatigue life, tribological properties, and distortion. In this paper, an experimental investigation was conducted to determine the effects of grinding force, temperature and grinding conditions, such as grinding speed, workpiece speed and grinding depth, on the surface and in-depth residual stresses distributions induced by grinding of 3J33 maraging steel with the miniature electroplated CBN Wheels. The results show that a ‘hook’ shaped residual stress profile is generated with the maximum compressive stresses occur at the depth of 3-14 ?m below the ground surface. There is a good correlation between residual stress and cutting force, but the trend related to grinding temperature is not obvious. The main grinding parameters affecting the residual stresses distributions is grinding speed, while the workpiece speed and grinding depth have the least effect.

scholarly journals Cross-Sectional Mapping of Residual Stresses by Measuring the Surface Contour After a Cut

2000 ◽  
Vol 123 (2) ◽  
pp. 162-168 ◽  
Author(s):  
M. B. Prime
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Superposition Principle ◽  
New Method ◽  
Contour Method ◽  
Stress Profile ◽  
Relaxation Methods ◽  
Cross Sectional ◽  
Residual Stress Profile

A powerful new method for residual stress measurement is presented. A part is cut in two, and the contour, or profile, of the resulting new surface is measured to determine the displacements caused by release of the residual stresses. Analytically, for example using a finite element model, the opposite of the measured contour is applied to the surface as a displacement boundary condition. By Bueckner’s superposition principle, this calculation gives the original residual stresses normal to the plane of the cut. This “contour method” is more powerful than other relaxation methods because it can determine an arbitrary cross-sectional area map of residual stress, yet more simple because the stresses can be determined directly from the data without a tedious inversion technique. The new method is verified with a numerical simulation, then experimentally validated on a steel beam with a known residual stress profile.

A Numerical Study on the Redistribution of Residual Stress After Machining

2017 ◽  
Author(s):  
Kunyang Lin ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Numerical Study ◽  
Cutting Speed ◽  
Machining Process ◽  
Stress Profile ◽  
Residual Stress Field ◽  
Machining Processes ◽  
Residual Stress Profile

Machining induced residual stresses have an important effect on the surface integrity. Effects of various factors on the distribution of residual stress profiles induced by different machining processes have been investigated by many researchers. However, the initial residual, as one of the important factor that affect the residual stress profile, is always been ignored. In this paper, the residual stress field induced by the quenching process is simulated by the FEM software as the initial condition. Then the initial residual stress field is used to study the residual stress redistribution after the machining process. The influence of initial stress on the stress formation is carried out illustrating with the mechanical and thermal loads during machining processes. The effects of cutting speed on the distribution of residual stress profile are also discussed. These results are helpful to understand how initial residual stresses are redistributed during machining better. Furthermore, the results in the numerical study can be used to explain the machining distortion problem caused by residual stress in the further work.

Residual Stress in Plain Carbon Steel Induced by Laser Hardening

2015 ◽  
Vol 812 ◽  
pp. 321-326 ◽  
Author(s):  
A. Filep ◽  
Márton Benke ◽  
Valéria Mertinger ◽  
Gábor Buza
Keyword(s):  
Heat Transfer ◽  
Residual Stress ◽  
Residual Stresses ◽  
Plain Carbon Steel ◽  
Laser Hardening ◽  
Manufacturing Processes ◽  
Stress Profile ◽  
Multiple Sources ◽  
Residual Stress Profile ◽  
Hardening Treatment

Technological residual stresses have great importance in the manufacturing processes and the lifetime of components. The residual stresses formed by quenching can be very diverse because of its multiple sources. Alternative quenching processes such as laser hardening have a great potential for different applications. The direction of heat transfer during laser hardening is the opposite compared to conventional quenching. This further increases the complexity of the developed stress state. The residual stress profile and the microstructure formed by laser hardening treatment are investigated in the present manuscript.

Experimental/Modelling Study of Residual Stress in Al/SiCp Bent Bars by Synchrotron XRD and Slitting Eigenstrain Methods

2008 ◽  
Vol 571-572 ◽  
pp. 277-282 ◽  
Author(s):  
Xu Song ◽  
Solène Chardonnet ◽  
Giancarlo Savini ◽  
Shu Yan Zhang ◽  
Willem J.J. Vorster ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Residual Strain ◽  
Numerical Models ◽  
Front Face ◽  
Stress Profile ◽  
X Ray Diffraction ◽  
Element Analysis ◽  
X Ray ◽  
Residual Stress Profile

The aim of the study presented here was to evaluate the residual stresses present in a bar of aluminium alloy 2124-T1 matrix composite (MMC) reinforced with 25vol% particulate silicon carbide (SiCp) using X-ray diffraction and 3D profilometry (curvature measurement using Mitutoyo/Renishaw coordinate measurement machine) and comparing these results with numerical models of residual strain and stress profiles obtained by a simple inelastic bending model and Finite Element Analysis (FEA). The residual strain distribution was introduced into the test piece by plastic deformation in the 4-point bending configuration. At the first stage of this study the elasticplastic behaviour of the MMC was characterized under static and cyclic loading to obtain the material parameters, hardening proprieties and cyclic hysteresis loops. Subsequently, synchrotron Xray diffraction and CMM curvature measurements were performed to deduce the residual stress profile in the central section of the bar. The experimental data obtained from these measurements were used in the inelastic bending and FEA simulations. The specimens were then subjected to incremental slitting using EDM (electric discharge machining) with continuous back and front face strain gauge monitoring. The X-ray diffraction and incremental slitting results were then analysed using direct and inverse eigenstrain methods. Residual stresses plots obtained by different methods show good agreement with each other.

Detailed Analysis of Residual Stress Profile at Micro-Scale in Transmission Laser Bonded Titanium/Polyimide System

2008 ◽  
Author(s):  
Ankitkumar P. Dhorajiya ◽  
Mohammed S. Mayeed ◽  
Gregory W. Auner ◽  
Ronald J. Baird ◽  
Golam M. Newaz ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Laser Beam ◽  
Stress Analysis ◽  
Detailed Analysis ◽  
Stress Profile ◽  
Fe Model ◽  
Residual Stress Profile ◽  
Stress Profiles ◽  
Residual Stress Analysis

Detailed analysis of residual stress profile due to laser micro-joining of two dissimilar biocompatible materials, polyimide (PI) and titanium (Ti), is vital for the long-term application of bio-implants. In this work, a comprehensive three dimensional (3D) transient model for sequentially coupled thermo-mechanical analysis of transmission laser micro-joining of two dissimilar materials has been developed by using the finite element (FE) code ABAQUS, along with a moving Gaussian laser heat source. The laser beam (wavelength of 1100 nm and diameter of 0.2 mm), moving at an optimized velocity, passes through the transparent PI, gets absorbed by the absorbing Ti, and eventually melts the PI to form the bond. The laser bonded joint area is 6.5 mm long by 0.3 mm wide. First the transient heat transfer analysis is performed and the nodal temperature profile has been achieved, and then used as an input for the residual stress analysis. Non-uniform mixed meshes have been used and optimized to formulate the 3D FE model and ensure very refined meshing around the bond area. Heat resistance between the two materials has been modeled by using the thermal surface interaction technique, and melting and solidification issues have been approximated in the residual stress analysis by using the appropriate material properties at corresponding temperature. First the model has been used to observe a good bonding condition with the laser parameters like laser traveling speed, power, and beam diameter (burnout temperature of PI > maximum temperature of PI achieved during heating > melting temperature of PI) and a good combination has been found to be 100 mm/min, 3.14 W and 0.2 mm respectively. Using this combination of parameters in heating, the residual stress profile of the laser-micro-joint has been calculated using FE model after cooling the system down to room temperature of 27 °C and analyzed in detail by plotting the stress profiles on the Ti and PI surfaces. Typically the residual stress profiles on the PI surface show low value in the middle, increase to higher values at about 160 μm from the centerline of the laser travel symmetrically at both sides, and to the contrary, on Ti surface show higher values near the centerline of traveling laser beam. The residual stresses have slowly dropped away on both the surfaces as the distance from the bond region increased further. Maximum residual stresses on both the Ti and PI surfaces are at the end of the laser travel, and are in the orders of the yield stresses of respective materials.

Application of the Eigenstrain Theory to Predict Residual Stress around Curved Edges after Laser Shock Peening

2013 ◽  
Vol 768-769 ◽  
pp. 185-192 ◽  
Author(s):  
Stefano Coratella ◽  
M. Burak Toparli ◽  
Michael E. Fitzpatrick
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Laser Shock Peening ◽  
Stress Profile ◽  
Laser Shock ◽  
Element Analysis ◽  
Residual Stress Profile ◽  
The Finite Element Analysis ◽  
Treatment Technologies ◽  
Shock Peening

Residual stresses play a fundamental role in mechanical engineering. They can be generated by manufacturing processes or introduced purposely by surface treatment technologies. One of the most recent technologies developed to introduce residual stresses is Laser Shock Peening. Since it is a relatively expensive technology, a fundamental role is played by the Finite Element Analysis approach to predict the final residual stress profile. The FEA approach consists of either direct simulation of the LSP process or the application of the eigenstrain approach. The application of the eigenstrain theory in predicting residual stresses after LSP treatment in curved edges is the subject of this research.

Finite Element Thermal/Mechanical Analysis of Transmission Laser Microjoining of Titanium and Polyimide

2009 ◽  
Vol 132 (1) ◽  
Author(s):  
Ankitkumar P. Dhorajiya ◽  
Mohammed S. Mayeed ◽  
Gregory W. Auner ◽  
Ronald J. Baird ◽  
Golam M. Newaz ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Dissimilar Materials ◽  
Optical Microscope ◽  
Mechanical Analysis ◽  
Maximum Temperature ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Thermal Mechanical Analysis

Detailed analysis of a residual stress profile due to laser microjoining of two dissimilar biocompatible materials, polyimide (PI) and titanium (Ti), is vital for the long-term application of bio-implants. In this work, a comprehensive three-dimensional (3D) transient model for sequentially coupled thermal/mechanical analysis of transmission laser (laser beam with wavelength of 1100 nm and diameter of 0.2 mm) microjoining of two dissimilar materials has been developed by using the finite element code ABAQUS, along with a moving Gaussian laser heat source. First the model has been used to optimize the laser parameters like laser traveling speed and power to obtain good bonding (burnout temperature of PI>maximum temperature of PI achieved during heating>melting temperature of PI) and a good combination has been found to be 100 mm/min and 3.14 W for a joint-length of 6.5 mm as supported by the experiment. The developed computational model has been observed to generate a bonding zone that is similar in width (0.33 mm) to the bond width of the Ti/PI joint observed experimentally by an optical microscope. The maximum temperatures measured at three locations by thermocouples have also been found to be similar to those observed computationally. After these verifications, the residual stress profile of the laser microjoint (100 mm/min and 3.14 W) has been calculated using the developed model with the system cooling down to room temperature. The residual stress profiles on the PI surface have shown low value near the centerline of the laser travel, increased to higher values at about 165 μm from the centerline symmetrically at both sides, and to the contrary, have shown higher values near the centerline on the Ti surface. Maximum residual stresses on both the Ti and PI surfaces are obtained at the end of laser travel, and are in the orders of the yield stresses of the respective materials. It has been explained that the patterned accumulation of residual stresses is due to the thermal expansion and contraction mismatches between the dissimilar materials at the opposite sides of the bond along with the melting and softening of PI during the joining process.

Residual Stress Profiles of Pipe Girth Weld Using a Stress Decomposition Method

2014 ◽  
Author(s):  
Huaguo Teng ◽  
Steve Bate
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Heuristic Method ◽  
Measurement Data ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Stress Components ◽  
Stress Profiles ◽  
Girth Welds

The application of procedures such as R6 or BS7910 for the structural assessment of defects in pressurised components containing residual stresses requires knowledge of the through-wall residual stress profile. Currently there is much interest in improving the residual stress profiles that are provided in the procedures. In this paper we present an improved analysis of residual stresses of the pipe girth welds by applying the developed heuristic method to one set of extended residual stress measurement data. The through-thickness residual stress is decomposed into three stress components: membrane, bending and self-equilibrating. The heuristic method was applied to the three components separately, so that the residual stress profile was a combination of the three stress components. This form provides not only a clear physical basis for the residual stress profile, but is also convenient for defect assessment where only the membrane and bending stress components are important.

Development of an Inverse Routine to Predict Residual Stresses in the Material Based on a Bending Test

2013 ◽  
Vol 554-557 ◽  
pp. 949-956 ◽  
Author(s):  
Akbar Abvabi ◽  
Bernard Rolfe ◽  
Peter Hodgson ◽  
Matthias Weiss
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Test Data ◽  
Bending Test ◽  
Roll Forming ◽  
Stress Profile ◽  
Forming Process ◽  
Residual Stress Profile ◽  
Difficult Time ◽  
Roll Forming Process

Bending with unloading and reverse bending are the dominant material deformations in roll forming and hence property data derived from bend tests could be more relevant than tensile test data for numerical simulation of the roll forming process. Recent investigations have shown that residual stresses affect the material behaviour close to the yield in a bending test. So, Residual stress introduced during prior steel processing may affect the roll forming process and therefore needs to be included in roll forming simulations to achieve improved model accuracy. Measuring the residual stress profile experimentally is expensive, difficult, time consuming and has limited accuracy. Analytical models are available that allow the determination of residual stress. However, for this detailed information about the pre-processing conditions is required; this information is generally not available for roll forming materials. The main goal of this study is to develop an inverse routine that generates a residual stress profile through the thickness of the material based on pure bend test data.

scholarly journals Effect of Laser Peening Process Parameters and Sequences on Residual Stress Profiles

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 655 ◽  
Author(s):  
Zina Kallien ◽  
Sören Keller ◽  
Volker Ventzke ◽  
Nikolai Kashaev ◽  
Benjamin Klusemann
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Process Parameters ◽  
Stress Component ◽  
Rolling Direction ◽  
Hole Drilling ◽  
Stress Profile ◽  
Laser Peening ◽  
Electron Backscattered Diffraction ◽  
Residual Stress Profile

Laser Peening (LP) is a surface modification technology that can induce high residual stresses in a metallic material. The relation between LP process parameters, in particular laser sequences, as well as pulse parameters and the resulting residual stress state was investigated in this study. The residual stress measurements, performed with the hole drilling technique, showed a non-equibiaxial stress profile in laser peened AA2024-T3 samples with a clad layer for certain parameter combinations. Shot overlap and applied energy density were found to be crucial parameters for the characteristic of the observed non-equibiaxial residual stress profile. Furthermore, the investigation showed the importance of the advancing direction, as the advancing direction influences the direction of the higher compressive residual stress component. The direction of higher residual stresses was parallel or orthogonal to the rolling direction of the material. The effect was correlated to the microstructural observation obtained via electron backscattered diffraction. Additionally, for peening with two sequences of different advancing directions, the study showed that the order of applied advancing directions was important for the non-equibiaxiality of the resulting residual stress profile.

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