Finite element analysis of thermal residual stresses at graded ceramic‐metal interfaces. Part II. Interface optimization for residual stress reduction

1993 ◽  
Vol 74 (2) ◽  
pp. 1321-1326 ◽  
Author(s):  
J. T. Drake ◽  
R. L. Williamson ◽  
B. H. Rabin
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Stress Reduction ◽  
Element Analysis ◽  
Thermal Residual Stresses ◽  
Metal Interfaces

scholarly journals Design optimization of precision casting for residual stress reduction

2015 ◽  
Vol 3 (2) ◽  
pp. 140-150 ◽  
Author(s):  
Appasaheb Adappa Keste ◽  
Shravan Haribhau Gawande ◽  
Chandrani Sarkar
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Design Optimization ◽  
Stress Reduction ◽  
Casting Process ◽  
Actual Behavior ◽  
Element Analysis ◽  
Cast Part

Abstract Normally all manufacturing and fabrication processes introduce residual stresses in a component. These stresses exist even after all service or external loads have been removed. Residual stresses have been studied elaborately in the past and even in depth research have been done to determine their magnitude and distribution during different manufacturing processes. But very few works have dealt with the study of residual stresses formation during the casting process. Even though these stresses are less in magnitude, they still result in crack formation and subsequent failure in later phases of the component usage. In this work, the residual stresses developed in a shifter during casting process are first determined by finite element analysis using ANSYS® Mechanical APDL, Release 12.0 software. Initially the analysis was done on a simple block to determine the optimum element size and boundary conditions. With these values, the actual shifter component was analyzed. All these simulations are done in an uncoupled thermal and structural environment. The results showed the areas of maximum residual stress. This was followed by the geometrical optimization of the cast part for minimum residual stresses. The resulting shape gave lesser and more evenly distributed residual stresses. Crack compliance method was used to experimentally determine the residual stresses in the modified cast part. The results obtained from the measurements are verified by finite element analysis findings. Highlights This paper focus on analytical, numerical and experimental design optimization of shifter. Performed design optimization by finite element analysis and experimental of live industrial problem. The results can applicable as a basis of design and optimization of new type of the automotive parts. The results of the current work present the actual behavior of induced stresses.

Fast Three-Dimensional Finite Element Analysis of Weld Overlay Application on a Formed Feeder Elbow

2011 ◽  
Author(s):  
Francis H. Ku ◽  
Pete C. Riccardella
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Nuclear Reactor ◽  
Three Dimensional ◽  
Fe Method ◽  
Element Analysis ◽  
Weld Overlay ◽  
Welding Processes

This paper presents a fast finite element analysis (FEA) model to efficiently predict the residual stresses in a feeder elbow in a CANDU nuclear reactor coolant system throughout the various stages of the manufacturing and welding processes, including elbow forming, Grayloc hub weld, and weld overlay application. The finite element (FE) method employs optimized FEA procedure along with three-dimensional (3-D) elastic-plastic technology and large deformation capability to predict the residual stresses due to the feeder forming and various welding processes. The results demonstrate that the fast FEA method captures the residual stress trends with acceptable accuracy and, hence, provides an efficient and practical tool for performing complicated parametric 3-D weld residual stress studies.

Estimation of Residual Stresses in Steel Welded Joints Using Three Dimensional Finite Element Analysis

2018 ◽  
Author(s):  
Shivdayal Patel ◽  
B. P. Patel ◽  
Suhail Ahmad
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Welding Speed ◽  
Welded Joints ◽  
Plate Thickness ◽  
Welding Process ◽  
Element Analysis

Welding is one of the most used joining methods in the ship industry. However, residual stresses are induced in the welded joints due to the rapid heating and cooling leading to inhomogenously distributed dimensional changes and non-uniform plastic and thermal strains. A number of factors, such as welding speed, boundary conditions, weld geometry, weld thickness, welding current/voltage, number of weld passes, pre-/post-heating etc, influence the residual stress distribution. The main aim of this work is to estimate the residual stresses in welded joints through finite element analysis and to investigate the effects of boundary conditions, welding speed and plate thickness on through the thickness/surface distributions of residual stresses. The welding process is simulated using 3D Finite element model in ABAQUS FE software in two steps: 1. Transient thermal analysis and 2. Quasi-static thermo-elasto-plastic analysis. The normal residual stresses along and across the weld in the weld tow region are found to be significant with nonlinear distribution. The residual stresses increase with the increase in the thickness of the plates being welded. The nature of the normal residual stress along the weld is found to be tensile-compressive-tensile and the nature of normal residual stress across the weld is found to be tensile along the thickness direction.

Probabilistic finite element analysis of residual stress formation in shrink-fit ceramic/steel gun barrels

2002 ◽  
Vol 216 (4) ◽  
pp. 219-231
Author(s):  
M Grujicic ◽  
J R DeLong ◽  
W S DeRossett
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Axial Stress ◽  
Sampling Technique ◽  
Cumulative Distribution ◽  
Element Analysis ◽  
Gun Barrel ◽  
Ceramic Lining

The development of residual stresses in a hybrid α-SiC lining/CrMoV steel jacket gun barrel during shrink fitting of the jacket over the lining is studied using a probabilistic finite element analysis. Particular attention is given to understanding the development of the axial compressive stress in the ceramic lining, since this stress (if sufficiently high) can prevent lining failure caused by formation and growth of circumferential cracks near the barrel ends. To quantify the effect of variability in various design, material and process parameters on the magnitude and the distribution of the axial residual stress, a probabilistic structural analysis approach, known as the advanced mean value (AMV) method, is used, enabling determination of the cumulative distribution function for failure of the lining. The results obtained are validated using the adaptive importance sampling (AIS) method, an efficient direct statistical sampling technique. Lastly, the corresponding sensitivity factors which quantify the effect of variability in each parameter on the magnitude of axial residual stresses in the ceramic lining are computed. The results indicate that the loss of the compressive axial stress in the lining near the barrel ends is affected to the greatest extent by the magnitude of the friction coefficient at the lining/barrel interface.

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