Finite Element Modeling of Hard Roller Burnishing: An Analysis on the Effects of Process Parameters Upon Surface Finish and Residual Stresses

2007 ◽  
Vol 129 (4) ◽  
pp. 705-716 ◽  
Author(s):  
Partchapol Sartkulvanich ◽  
Taylan Altan ◽  
Francisco Jasso ◽  
Ciro Rodriguez
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Process Parameters ◽  
Surface Finish ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Cost Effective ◽  
Machined Surface ◽  
Fem Model ◽  
Roller Burnishing

Hard roller burnishing is a cost-effective finishing and surface enhancement process where a ceramic ball rolls on the machined surface to flatten the roughness peaks. The ball is supported and lubricated by hydrostatic fluid in a special tool holder. The process not only improves surface finish but also imposes favorable compressive residual stresses in functional surfaces, which can lead to long fatigue life. Most research in the past focused on experimental studies. There is still a special need for a reliable finite element method (FEM) model that provides a fundamental understanding of the process mechanics. In this study, two-dimensional (2D) and three-dimensional FEM models for hard roller burnishing were established. The developed 2D FEM model was used to study the effects of process parameters (i.e., burnishing pressure, feed rate) on surface finish and residual stresses. The simulation results were evaluated and compared to the experimental data. Results show that the established FEM model could predict the residual stresses and provided useful information for the effect of process parameters. Both FEM and experiments show that burnishing pressure is the most influence, where high burnishing pressure produces less roughness and more compressive residual stress at the surface.

Numerical and Experimental Studies of Residual Stresses in Cold Expanded Holes

2012 ◽  
Vol 488-489 ◽  
pp. 1282-1287 ◽  
Author(s):  
H.D. Gopalakrishna ◽  
Vinod M. Srinivasa
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Strain Gauges ◽  
Maximum Deviation ◽  
Element Analysis ◽  
Hole Expansion ◽  
Al 2024

This paper presents the numerical and experimental studies of the residual stresses in Al 2024 T3 specimens due to cold hole expansion (CHE) using ball and taper mandrel techniques. A three dimensional, non-linear finite element analysis has been performed to simulate the CHE process and experiments were conducted to determine the residual stresses due to CHE with 2 - 6 % expansion of holes. The residual stresses were determined experimentally by employing strain gauges around the hole during the expansion. Experimental and Finite Element Analysis (FEA) results showed that the residual stresses increased up to 5 % of hole expansion and decreased further in both the techniques of CHE and the same were greater in case of tapered mandrel than that of ball mandrel method. At the optimum expansion of 5%, the FE predictions and experimental results concurred with each other with a maximum deviation of 2%.

Optimization of the Wrist Pin End of an Automobile Engine Connecting Rod With an Interference Fit

1990 ◽  
Vol 112 (3) ◽  
pp. 406-412 ◽  
Author(s):  
Vijay Sarihan ◽  
Ji Oh Song
Keyword(s):  
Finite Element ◽  
Optimum Design ◽  
Three Dimensional ◽  
Stress Singularity ◽  
Design Strategy ◽  
Structural Components ◽  
Connecting Rod ◽  
Fem Model ◽  
Automobile Engine ◽  
Interference Fit

Current design procedures for complicated three-dimensional structural components with component interactions may not necessarily result in optimum designs. The wrist pin end design of the connecting rod with an interference fit is governed by the stress singularity in the region where the wrist pin breaks contact with the connecting rod. Similar problems occur in a wide variety of structural components which involve interference fits. For a better understanding of the problems associated with obtaining optimum designs for this important class of structural interaction only the design problems associated with the wrist pin end of the rod are addressed in this study. This paper demonstrates a procedure for designing a functional and minimum weight wrist pin end of an automobile engine connecting rod with an interference fit wrist pin. Current procedures for Finite Element Method (FEM) model generation in complicated three-dimensional components are very time consuming especially in the presence of stress singularities. Furthermore the iterative nature of the design process makes the process of developing an optimum design very expensive. This design procedure uses a generic modeler to generate the FEM model based on the values of the design variables. It uses the NASTRAN finite element program for structural analysis. A stress concentration factor approach is used to obtain realistic stresses in the region of the stress singularity. For optimization, the approximate optimization strategy in the COPES/CONMIN program is used to generate an approximate design surface, determine the design sensitivities for constrained function minimization and obtain the optimum design. This proposed design strategy is fully automated and requires only an initial design to generate the optimum design. It does not require analysis code modifications to compute the design sensitivities and requires very few costly NASTRAN analyses. The connecting rod design problem was solved as an eight design variable problem with five constraints. A weight reduction of nearly 27 percent was achieved over an existing design and required only thirteen NASTRAN analyses. It is felt that this design strategy can be effectively used in an engineering environment to generate optimum designs of complicated three-dimensional components.

scholarly journals Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

2021 ◽  
pp. 146442072198974
Author(s):  
A Ktari ◽  
A Abdelkefi ◽  
N Guermazi ◽  
P Malecot ◽  
N Boudeau
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Plastic Flow ◽  
Tube Hydroforming ◽  
Three Dimensional ◽  
Element Model ◽  
Tube Cross Section ◽  
Straight Wall ◽  
Hydroforming Process

During tube hydroforming process, the friction conditions between the tube and the die have a great importance on the material plastic flow and the distribution of residual stresses of the final component. Indeed, a three-dimensional finite element model of a tube hydroforming process in the case of square section die has been performed, using dynamic and static approaches, to study the effect of the friction conditions on both plastic flow and residual stresses induced by the process. First, a comparative study between numerical and experimental results has been carried out to validate the finite element model. After that, various coefficients of friction were considered to study their effect on the thinning phenomenon and the residual stresses distribution. Different points have been retained from this study. The thinning is located in the transition zone cited between the straight wall and the corner zones of hydroformed tube due to the die–tube contact conditions changes during the process. In addition, it is clear that both die–tube friction conditions and the tube bending effects, which occurs respectively in the tube straight wall and corner zones, are the principal causes of the obtained residual stresses distribution along the tube cross-section.

scholarly journals Analysis of Forces in Vibro-Impact and Hot Vibro-Impact Turning of Advanced Alloys

2011 ◽  
Vol 70 ◽  
pp. 315-320 ◽  
Author(s):  
Riaz Muhammad ◽  
Agostino Maurotto ◽  
Anish Roy ◽  
Vadim V. Silberschmidt
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Element Model ◽  
Machining Process ◽  
Strain Rates ◽  
Machining Processes ◽  
Machined Surface ◽  
Cutting Zone

Analysis of the cutting process in machining of advanced alloys, which are typically difficult-to-machine materials, is a challenge that needs to be addressed. In a machining operation, cutting forces causes severe deformations in the proximity of the cutting edge, producing high stresses, strain, strain-rates and temperatures in the workpiece that ultimately affect the quality of the machined surface. In the present work, cutting forces generated in a vibro-impact and hot vibro-impact machining process of Ti-based alloy, using an in-house Ultrasonically Assisted Turning (UAT) setup, are studied. A three-dimensional, thermo-mechanically coupled, finite element model was developed to study the thermal and mechanical processes in the cutting zone for the various machining processes. Several advantages of ultrasonically assisted turning and hot ultrasonically assisted turning are demonstrated when compared to conventional turning.

scholarly journals Prediction of Residual Stresses in a Multipass Pipe Weld by a Novel 3D Finite Element Approach

2018 ◽  
Author(s):  
Hui Huang ◽  
Jian Chen ◽  
Blair Carlson ◽  
Hui-Ping Wang ◽  
Paul Crooker ◽  
...  
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
High Performance ◽  
Large Scale ◽  
Graphics Processing Unit ◽  
Computational Cost ◽  
Three Dimensional ◽  
Processing Unit ◽  
Girth Welds ◽  
Welding Processes

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

A Biomechanical Model of Lumbar Spine

2000 ◽  
Author(s):  
Subramanya Uppala ◽  
Robert X. Gao ◽  
Scott Cowan ◽  
K. Francis Lee
Keyword(s):  
Finite Element ◽  
Lumbar Spine ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Biomechanical Model ◽  
Element Model ◽  
Fe Model ◽  
Flexion Extension ◽  
Cortical Shell ◽  
Three Dimensional Finite Element

Abstract The strength and stability of the lumbar spine are determined not only by the bone and muscles, but also by the visco-elastic structures and the interplay between the different components of the spine, such as ligaments, capsules, annulus fibrosis, and articular cartilage. In this paper we present a non-linear three-dimensional Finite Element model of the lumbar spine. Specifically, a three-dimensional FE model of the L4-5 one-motion segment/2 vertebrae was developed. The cortical shell and the cancellous bone of the vertebral body were modeled as 3D isoparametric eight-nodal elements. Finite element models of spinal injuries with fixation devices are also developed. The deformations across the different sections of the spine are observed under the application of axial compression, flexion/extension, and lateral bending. The developed FE models provided input to both the fixture design and experimental studies.

Additive Manufacturing of Porous Ceramics with Foaming Agent

2021 ◽  
pp. 1-21
Author(s):  
Zipeng Guo ◽  
Lu An ◽  
Sushil Lakshmanan ◽  
Jason Armstrong ◽  
Shenqiang Ren ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ambient Pressure ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Cost Effective ◽  
Tensile Tests ◽  
Porous Ceramics ◽  
Foaming Agent ◽  
Printing Quality ◽  
And Control

Abstract The macro-porous ceramics has promising durability and thermal insulation performance. As porous ceramics find more and more applications across many industries, a cost-effective and scalable additive manufacturing technique for fabricating macro-porous ceramics is highly desirable. Herein, we reported a facile additive manufacturing approach to fabricate porous ceramics and control the printed porosity. Several printable ceramic inks were prepared, the foaming agent was added to generate gaseous bubbles in the ink, followed by the direct ink writing and the ambient-pressure and room-temperature drying to create the three-dimensional geometries. A set of experimental studies were performed to optimize the printing quality. The results revealed the optimal process parameters for printing the foamed ceramic ink with a high spatial resolution and fine surface quality. Varying the concentration of the foaming agent enables the controllability of the structural porosity. The maximum porosity can reach 85%, with a crack-free internal porous structure. The tensile tests showed that the printed macro-porous ceramics possessed enhanced durability with the addition of fiber. With a high-fidelity 3D printing process and the precise controllability of the porosity, we showed that the printed samples exhibited a remarkably low thermal conductivity and durable mechanical strength.

scholarly journals Increasing Damping of Thin-Walled Structures Using Additively Manufactured Vibration Eliminators

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2125 ◽  
Author(s):  
Paweł Dunaj ◽  
Stefan Berczyński ◽  
Karol Miądlicki ◽  
Izabela Irska ◽  
Beata Niesterowicz
Keyword(s):  
Finite Element ◽  
Dynamic Stiffness ◽  
Experimental Studies ◽  
Steel Beam ◽  
Finite Element Models ◽  
Fem Model ◽  
Thin Walled Structures ◽  
Resonance Frequencies ◽  
Thin Walled ◽  
Parametric Analyses

The paper presents a new way to conduct passive elimination of vibrations consisting of covering elements of structures with low dynamic stiffness with polylactide (PLA). The PLA cover was created in 3D printing technology. The PLA cover was connected with the structure by means of a press connection. Appropriate arrangement of the PLA cover allows us to significantly increase the dissipation properties of the structure. The paper presents parametric analyses of the influence of the thickness of the cover and its distribution on the increase of the dissipation properties of the structure. Both analyses were carried out using finite element models (FEM). The effectiveness of the proposed method of increasing damping and the accuracy of the developed FEM models was verified by experimental studies. As a result, it has been proven that the developed FEM model of a free-free steel beam covered with polylactide enables the mapping of resonance frequencies at a level not exceeding 0.6% of relative error. Therefore, on its basis, it is possible to determine the parameters of the PLA cover. Comparing a free-free steel beam without cover with its PLA-covered counterpart, a reduction in the amplitude levels of the receptance function was achieved by up to 90%. The solution was validated for a steel frame for which a 37% decrease in the amplitude of the receptance function was obtained.

Sign in / Sign up

Export Citation Format

Share Document