Microstructure-Level Model for the Prediction of Tool Failure in WC-Co Cutting Tool Materials

2006 ◽  
Vol 128 (3) ◽  
pp. 739-748 ◽  
Author(s):  
Sunghyuk Park ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
Finite Element ◽  
Equivalent Stress ◽  
Mixed Mode Fracture ◽  
Tool Failure ◽  
Tool Materials ◽  
Microstructural Parameters ◽  
Model Predictions ◽  
Level Model ◽  
Mixed Mode Fracture Criterion ◽  
Co Alloys

A model to predict tool failure due to chipping in machining via the microstructure-level finite element cutting process simulation is presented and applied to a wide variety of WC-Co tool materials. The methodology includes the creation of arbitrary microstructures comprised of WC and Co phases to simulate various grades of WC-Co alloys. Equivalent stress, strain, and strain energy are then obtained via orthogonal microstructure-level finite element machining simulations. A model was developed to predict the occurrence of tool failure based on the mixed mode fracture criterion. Turning experiments were conducted to validate the model and the results showed that the model predictions agree well with the observations from the experiments. The model was then employed to study the effects of microstructural parameters and feedrate on chipping and failure.

scholarly journals Finite Element Modeling of Residual Stress at Joint Interface of Titanium Alloy and 17-4PH Stainless Steel

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 629
Author(s):  
Nana Kwabena Adomako ◽  
Sung Hoon Kim ◽  
Ji Hong Yoon ◽  
Se-Hwan Lee ◽  
Jeoung Han Kim
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Finite Element Modeling ◽  
Equivalent Stress ◽  
Stress Gradient ◽  
Joint Interface ◽  
Element Modeling ◽  
Actual Experiment ◽  
Maximum Equivalent Stress

Residual stress is a crucial element in determining the integrity of parts and lifetime of additively manufactured structures. In stainless steel and Ti-6Al-4V fabricated joints, residual stress causes cracking and delamination of the brittle intermetallic joint interface. Knowledge of the degree of residual stress at the joint interface is, therefore, important; however, the available information is limited owing to the joint’s brittle nature and its high failure susceptibility. In this study, the residual stress distribution during the deposition of 17-4PH stainless steel on Ti-6Al-4V alloy was predicted using Simufact additive software based on the finite element modeling technique. A sharp stress gradient was revealed at the joint interface, with compressive stress on the Ti-6Al-4V side and tensile stress on the 17-4PH side. This distribution is attributed to the large difference in the coefficients of thermal expansion of the two metals. The 17-4PH side exhibited maximum equivalent stress of 500 MPa, which was twice that of the Ti-6Al-4V side (240 MPa). This showed good correlation with the thermal residual stress calculations of the alloys. The thermal history predicted via simulation at the joint interface was within the temperature range of 368–477 °C and was highly congruent with that obtained in the actual experiment, approximately 300–450 °C. In the actual experiment, joint delamination occurred, ascribable to the residual stress accumulation and multiple additive manufacturing (AM) thermal cycles on the brittle FeTi and Fe2Ti intermetallic joint interface. The build deflected to the side at an angle of 0.708° after the simulation. This study could serve as a valid reference for engineers to understand the residual stress development in 17-4PH and Ti-6Al-4V joints fabricated with AM.

Elasto-plastic and creep behaviour of axially loaded, shouldered tubes

1980 ◽  
Vol 15 (1) ◽  
pp. 21-29 ◽  
Author(s):  
R J Dawson ◽  
H Fessler ◽  
T H Hyde ◽  
J J Webster
Keyword(s):  
Finite Element ◽  
Creep Behaviour ◽  
Equivalent Stress ◽  
Strain Curve ◽  
Equivalent Strain ◽  
Uniaxial Tensile ◽  
Plastic Strain Increment ◽  
Axially Loaded ◽  
Initial Strains ◽  
Creep Strains

This paper compares the finite element predictions of elasto-plastic and creep behaviour with experimental data for axially loaded, shouldered tube models. Four shouldered tube models were made of a lead alloy and tested at 61°C, using strain gauges to measure the elasto-plastic and creep strains in the plain tube and fillet regions of the models. Instantaneous stress-strain and creep data were obtained from strain-gauged, uniaxial tensile specimens. The finite element solutions are based on the incremental Prandtl-Reuss equations. The elasto-plastic iterative solutions use a ‘negative gradient’ from the calculated point to the equivalent stress-equivalent strain curve to get the next estimate of the plastic strain increment. A time incremental method is used to obtain the creep solutions. Tests with the mean tube stress below, at and above the yield stress showed very good agreement between prediction and measurement of initial strains in the fillets. Differences between predictions and measurements of creep strains are attributable to cast-to-cast variations.

A new mixed-mode fracture criterion of anisotropic rock

2021 ◽  
pp. 107730
Author(s):  
Dong-Liang Sun ◽  
Qiu-hua Rao ◽  
Shan-Yong Wang ◽  
Wei Yi ◽  
Qing-qing Shen
Keyword(s):  
Mixed Mode ◽  
Fracture Criterion ◽  
Mixed Mode Fracture ◽  
Anisotropic Rock ◽  
Mode Fracture ◽  
Mixed Mode Fracture Criterion

Rigid-Plastic Impact of Single Angular Particles

2021 ◽  
Author(s):  
Sandeep Dhar
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Orientation Dependence ◽  
Particle Orientation ◽  
Rigid Plastic ◽  
Plastic Model ◽  
Model Predictions ◽  
Good Agreement ◽  
Angular Particles

The trajectory of an angular particle as it cuts a ductile target is, in general, complicated because of its dependence not only on particle shape, but also on particle orientation at the initial instant of impact. This orientation dependence has also made experimental measurement of impact parameters of single angular particles very difficult, resulting in a relatively small amount of available experimental data in the literature. The current work is focused on obtaining measurements of particle kinematics for comparison to rigid plastic model developed by Papini and Spelt. Fundamental mechanisms of material removal are identified, and measurements of rebound parameters and corresponding crater dimensions of single hardened steel particles launched against flat aluminium alloy targets are presented. Also a 2-D finite element model is developed and a dynamic analysis is performed to predict the erosion mechanism. Overall, a good agreement was found among the experimental results, rigid-plastic model predictions and finite element model predictions.

Optimization design of titanium alloy connecting rod based on structural topology optimization

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bin Zheng ◽  
Yi Cai ◽  
Kelun Tang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Optimization Design ◽  
Equivalent Stress ◽  
Connecting Rod ◽  
Element Analysis ◽  
Content Type ◽  
The Finite Element Analysis ◽  
Maximum Equivalent Stress

Purpose The purpose of this paper is to realize the lightweight of connecting rod and meet the requirements of low energy consumption and vibration. Based on the structural design of the original connecting rod, the finite element analysis was conducted to reduce the weight and increase the natural frequencies, so as to reduce materials consumption and improve the energy efficiency of internal combustion engine. Design/methodology/approach The finite element analysis, structural optimization design and topology optimization of the connecting rod are applied. Efficient hybrid method is deployed: static and modal analysis; and structure re-design of the connecting rod based on topology optimization. Findings After the optimization of the connecting rod, the weight is reduced from 1.7907 to 1.4875 kg, with a reduction of 16.93%. The maximum equivalent stress of the optimized connecting rod is 183.97 MPa and that of the original structure is 217.18 MPa, with the reduction of 15.62%. The first, second and third natural frequencies of the optimized connecting rod are increased by 8.89%, 8.85% and 11.09%, respectively. Through the finite element analysis and based on the lightweight, the maximum equivalent stress is reduced and the low-order natural frequency is increased. Originality/value This paper presents an optimization method on the connecting rod structure. Based on the statics and modal analysis of the connecting rod and combined with the topology optimization, the size of the connecting rod is improved, and the static and dynamic characteristics of the optimized connecting rod are improved.

Thermo-mechanical analysis and optimization of functionally graded rotating disks

2020 ◽  
Vol 55 (5-6) ◽  
pp. 159-171
Author(s):  
Hassan Mohamed Abdelalim Abdalla ◽  
Daniele Casagrande ◽  
Luciano Moro
Keyword(s):  
Finite Element ◽  
Equivalent Stress ◽  
Rotating Disk ◽  
Mechanical Analysis ◽  
Theory Of Elasticity ◽  
Functionally Graded ◽  
Rotating Disks ◽  
Maximum Equivalent Stress ◽  
Quadratic Programming Method ◽  
Stress Uniformity

The behavior of thermo-mechanical stresses in functionally graded axisymmetric rotating hollow disks with variable thickness is analyzed. The material is assumed to be functionally graded in the radial direction. First, a two-dimensional axisymmetric model of the functionally graded rotating disk is developed using the finite element method. Exact solutions for stresses are then obtained assuming that the plane theory of elasticity holds. These solutions are in accordance with finite element ones, thus showing the validity of the assumption. Finally, in order to reduce the maximum equivalent stress along the radius, the optimization of the material distribution is addressed. To avoid subsequent finite element simulations in the optimization process, which can be computationally demanding, a nonlinear constrained optimization problem is proposed, for which the solution is obtained numerically by the sequential quadratic programming method, showing prominent results in terms of equivalent stress uniformity.

3D FEA Modeling of Hard Turning

2002 ◽  
Vol 124 (2) ◽  
pp. 189-199 ◽  
Author(s):  
Y. B. Guo ◽  
C. R. Liu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Geometric Model ◽  
Friction Model ◽  
Dominant Factor ◽  
Analysis Model ◽  
Element Analysis ◽  
Plastic Properties ◽  
Fea Model ◽  
Model Predictions

A practical explicit 3D finite element analysis model has been developed and implemented to analyze turning hardened AISI 52100 steels using a PCBN cutting tool. The finite element analysis incorporated the thermo-elastic-plastic properties of the work material in machining. An improved friction model has been proposed to characterize tool-chip interaction with the friction coefficient and shear flow stresses determined by force calibration and material tests, respectively. A geometric model has been established to simulate a 3D turning. FEA Model predictions have reasonable accuracy for chip geometry, forces, residual stresses, and cutting temperatures. FEA model sensitivity analysis indicates that the prediction is consistent using a suitable magnitude of material failure strain for chip separation, the simulation gives reasonable results using the experimentally determined material properties, the proposed friction model is valid and the sticking region on the tool-chip interface is a dominant factor of model predictions.

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