Modeling of residual stresses by correlating surface topography in machining of AISI 52100 steel

2021 ◽  
pp. 1-26
Author(s):  
Chao Liu ◽  
Yan He ◽  
Yufeng Li ◽  
Yulin Wang ◽  
Shilong Wang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Force ◽  
Surface Topography ◽  
Analytical Model ◽  
Analytical Models ◽  
Workpiece Surface ◽  
Dynamic Cutting Force ◽  
Intermittent Cutting ◽  
Effect Of Surface

Abstract The residual stresses could affect the ability of components to bear loading conditions and also the performance. The researchers considered workpiece surface as a plane and ignored the effect of surface topography induced by the intermittent cutting process when modeling residual stresses. The aim of this research develops an analytical model to predict workpiece residual stresses during intermittent machining by correlating the effect of surface topography. The relative motions of tool and workpiece are analyzed for modeling thermal-mechanical and surface topography. The influence of dynamic cutting force and thermal on different positions of surface topography is also considered in analytical model. Then the residual stresses model with the surface topography effect can be developed in intermittent cutting. The analytical models of dynamic cutting force, surface topography and residual stresses are verified by the experiments. The variation trend of evaluated values of the residual stress of workpiece is basically consistent with that of measured values. The compressive residual stress of workpiece surface in highest point of the surface topography are higher than that in the lowest point.

scholarly journals Analytical and Experimental Study of Residual Stresses in Thermal Barrier Coatings Deposited on Gas Turbine Blades in Laboratory Dimensions by APS and HVOF Methods to Calculate the Optimal Thickness

2021 ◽  
Vol 3 (1) ◽  
pp. 63-67
Author(s):  
Esmaeil Poursaeidi ◽  
◽  
Farzam Montakhabi ◽  
Javad Rahimi ◽  
◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Analytical Model ◽  
Thermal Barrier Coatings ◽  
Gas Turbines ◽  
Turbine Blades ◽  
Thermal Barrier ◽  
Inlet Temperature ◽  
Optimal Thickness ◽  
Barrier Coatings

The constant need to use gas turbines has led to the need to increase turbines' inlet temperature. When the temperature reaches a level higher than the material's tolerance, phenomena such as creep, changes in mechanical properties, oxidation, and corrosion occur at high speeds, which affects the life of the metal material. Nowadays, operation at high temperatures is made possible by proceedings such as cooling and thermal insulation by thermal barrier coatings (TBCs). The method of applying thermal barrier coatings on the turbine blade creates residual stresses. In this study, residual stresses in thermal barrier coatings applied by APS and HVOF methods are compared by Tsui–Clyne analytical model and XRD test. The analytical model results are in good agreement with the experimental results (between 2 and 8% error), and the HVOF spray method creates less residual stress than APS. In the end, an optimal thickness for the coating is calculated to minimize residual stress at the interface between the bond coat and top coat layers.

Early Developments for a Semi-Analytical Model of Weld Induced Residual Stress

2007 ◽  
Author(s):  
Jess M. Bromley ◽  
Hassan Alizadeh ◽  
David J. Smith ◽  
Christopher E. Truman
Keyword(s):  
Residual Stress ◽  
Analytical Model ◽  
Thermal Processing ◽  
Complete Solution ◽  
Analytical Models ◽  
Thermal Processes ◽  
Rapid Testing ◽  
Plastic Slip ◽  
Computationally Expensive ◽  
The Given

The generation of plastic slip and residual stress by thermal processes is particularly difficult to understand and simulate. Modelling such problems is computationally expensive when approached numerically and extremely complex to approach analytically. ‘Semi-analytical’ models, in which analytical thermoelastic solutions are combined with approximate models of plasticity, offer a way to bridge this gap and have the potential to allow the rapid testing of parameter sensitivities before one launches a time-consuming full numerical model. However the construction of such models within such a thermal framework poses its own problems. An initial requirement for any such semi-analytical model is a complete solution to the elastic only response of the material to the given loading process. In this paper we focus on the formulation of such a solution for the simplest case relevant to welding or similar thermal processing. We verify the solution developed against finite element predictions and then further investigate it. In doing so we explain how the nature of this solution, especially its predicted yielding behaviour, has ramifications for the successful creation of a full semi-analytical solution.

Effect of Surface Roughness and Residual Stress Induced by High Speed Milling Process on Short Crack Growth

2016 ◽  
Author(s):  
B. Zheng ◽  
H. D. Yu ◽  
X. Wang ◽  
X. M. Lai
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Residual Stresses ◽  
Crack Growth ◽  
Damage Evolution ◽  
High Speed ◽  
Milling Process ◽  
Short Crack ◽  
Machining Process ◽  
Effect Of Surface

Surface scratches and residual stresses inevitably appear on the surface of the component as a result of the machining process. The damage evolution of surface scratch due to the combined effect of cyclic loading and residual stresses will be significantly different from the case where only the cyclic loading is considered. In the damage evolution of surface scratch, the short crack growth is of great importance owing to its apparently anomalous behaviors compared with the long-crack growth. In this paper, the effect of the surface roughness and the residual stress on the short crack growth is studied. Firstly, the surface roughness and the residual stress of 7075-T6 aluminum alloy induced by the high speed milling process with various cutting speeds and feed rates are investigated with the experimental method. The maximum height roughness parameter is measured, which is regarded as the surface defect induced by the milling process. The residual stress on the specimen surface is measured with the X-ray diffraction. Results show that the surface roughness becomes higher with the increase of the feed rate. However, the influence of the cutting speed on the surface roughness is not significant. The residual stresses on the specimen surface are all in the compressive state. The residual stress is more compressive as the feed rate increases. The effects of the process parameters on the surface roughness and the residual stress are described by the fitted formulas. Then a modified model is built to characterize short fatigue crack growth behaviors with the consideration of the residual stress. This model is proved to provide a realistic treatment of the short crack growth, as reflected by comparison with experimental fatigue crack growth data of medium carbon steel and 7075-T6 aluminum alloy published in literature. The effect of surface roughness and residual stress caused by the milling process on the short crack growth is also investigated by using the proposed model. The growth of the scratch is nonlinear when it is subjected to the cyclic load. The compressive residual stress reduces the growth rate of the crack. The crack with larger initial surface roughness grows faster than that with smaller roughness. The correlation of surface roughness, residual stress and crack growth length is obtained by the polynomial fitting. The investigations in this paper can help the damage tolerance design of structures and improve the awareness of the effect of the residual stress and surface roughness induced by the machining process on the short crack growth.

Residual Stresses in Al2O3-ZrO2 Laminar System

2005 ◽  
Vol 290 ◽  
pp. 264-267 ◽  
Author(s):  
Peter Zimovčák ◽  
Tibor Köves ◽  
Ján Dusza ◽  
Francis Chalvet ◽  
Goffredo de Portu
Keyword(s):  
Thermal Stress ◽  
Residual Stresses ◽  
Analytical Model ◽  
Thermal Stresses ◽  
Analytical Models ◽  
Indentation Method ◽  
Model Validity

The aim of the paper is to present an analytical model of thermal stresses in a laminar system, and consequently to verify the model validity by comparing calculated thermal stresses with measured ones by indentation method. Analytical models of thermal stresses acting in anisotropic and isotropic laminar plane systems are presented, and consequently applied to the thermal-stress-strengthened Al2O3-ZrO2 laminar ceramics.

Analysis of Residual Stresses in Micro Powder Injection Moulded Micro Bending Specimens Made of Zirconia

2005 ◽  
Vol 490-491 ◽  
pp. 503-508 ◽  
Author(s):  
B. Kasanická ◽  
Thomas Wroblewski ◽  
Volker Schulze ◽  
Detlef Löhe
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Electron Microscope ◽  
Residual Stresses ◽  
Surface Topography ◽  
Powder Injection ◽  
Residual Stress State ◽  
Powder Injection Moulding ◽  
Sintering Conditions ◽  
Scanning Electron

Analysis of the residual stress state, the microstructure and surface topography of ceramic microcomponents made of Y2O3-stabilized ZrO2 produced by micro powder injection moulding were performed. During the production of the microspecimens sintering conditions were varied. The measurement of residual stresses has been carried out using the MAXIM (MAterials XRay IMaging) diffractometer at HASYLAB beamline G3 at DESY in Hamburg (Germany). The microstructure and surface topography of differently moulded specimens were examined using a scanning electron microscope (SEM) and a confocal white light microscope type NANOFOCUS. The findings are used to establish correlations between process parameters and characteristics of the microcomponents. These will allow to improve the production process with respect to the mechanical properties of the microcomponents.

Modelling of Residual Stresses Induced by Turning of 316L

2009 ◽  
Vol 83-86 ◽  
pp. 230-236 ◽  
Author(s):  
F. Valiorgue ◽  
J. Rech ◽  
H. Hamdi ◽  
P. Gilles ◽  
J.M. Bergheau
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Parameters ◽  
Stress Generation ◽  
Workpiece Surface ◽  
New Approach ◽  
Residual Stress State ◽  
Cutting Operation ◽  
Experimental Works ◽  
The Impact

Residual stresses are very important for the lifetime of pieces in their mechanisms. These kind of damages are mainly caused by mechanical, thermal, and metallurgical affectations of the machined material. To control these affectations, we need to link the cutting parameters to the residual stress state observed onto the workpiece surface and depth. These connections can be made with analytical works, experimental works or numerical works. In our case, it has been chosen to work with a numerical support in order to observe and understand precisely the phenomenon involved during cutting operation. While this way of study is really popular, we proposed to model the residual stress generation in a original way by keeping aside the chip formation. This new approach presented in a previous paper was simple and only use a 2D model. This first model moves thermo mechanical loadings onto the workpiece surface to recreate the relative motion between the tool and the workpiece. The new 3D model, presented in this paper, is now improved with an original friction law. It underlines the impact of each passage of the tool onto the others. The physical properties are thermo dependant and the flow stress model is based on a Johnson cook behaviour.

Analytical and Experimental Approach of Residual Stress on Deep-Rolled Crankshafts and Auto-Fretted Diesel Injection Rails. Effect on Fatigue Resistances in Service

2011 ◽  
Vol 681 ◽  
pp. 261-266 ◽  
Author(s):  
H. Michaud ◽  
Jean Michel Sprauel
Keyword(s):  
Residual Stress ◽  
High Pressure ◽  
Residual Stresses ◽  
Analytical Model ◽  
Fatigue Damage ◽  
Fatigue Resistance ◽  
Experimental Approach ◽  
Industrial Process ◽  
Diesel Injection ◽  
Fatigue Criterion

The fatigue resistance of car components such as crankshafts or diesel injection rails is mainly related to fatigue at geometrical singularities. Its understanding requires the simulations of the different steps of the industrial process resulting in residual stresses generation and their evolutions in service. First concerning crankshaft fatigue damage, a complete analytical model of residual stresses generation and shakedown in fatigue is presented. Then a fatigue criterion is established and validated for this application. Finally, for the high pressure diesel injection rail, this approach can be generalized to the holes intersection singularities.

Research on Cutting Residual Stresses Based on Thermo-Mechanical Coupling

2009 ◽  
Vol 628-629 ◽  
pp. 651-656
Author(s):  
Ying Qiang Xu ◽  
S.J. Li ◽  
T. Zhang ◽  
X.H. Yang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Cutting Speed ◽  
Element Model ◽  
Stress Generation ◽  
Workpiece Surface ◽  
Mechanical Coupling ◽  
Basic Parameters

Mathematical models of basic parameters, force and thermal parameters of cutting were obtained by applying the thermo-elastic-plastic theory and the heat-balance theory, according to the principle of residual stress generation in cutting process. Based on the 2D finite element model of chip molding with separation surface, the direct way was applied in thermo-mechanical coupling, and residual stress of cutting GH4169 were simulated and analyzed by finite element. The results showed that the residual stresses are changed from tensile to compressive with the development of depth away from the workpiece surface. Also its values are changed according to a certain rule as varying the cutting speed. These provide a foundation for the control of cutting quality of workpiece.

Surface Integrity of Die Material in High Speed Hard Machining, Part 2: Microhardness Variations and Residual Stresses

1999 ◽  
Vol 122 (4) ◽  
pp. 632-641 ◽  
Author(s):  
T. I. El-Wardany ◽  
H. A. Kishawy ◽  
M. A. Elbestawi
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stress Distribution ◽  
Residual Stresses ◽  
High Speed ◽  
Residual Stress Distribution ◽  
Depth Of Cut ◽  
Hard Machining ◽  
Machined Surface ◽  
Workpiece Surface

The main objective of this paper is to investigate the quality and integrity of the surface produced during high speed hard machining (HSHM) of D2 tool steel in its hardened state (60–62 HRc). Polycrystalline Cubic Boron Nitride (PCBN) tools are used in this study. The results obtained from the micro-graphical analysis of the surface produced are presented in Part 1 of this paper. In Part 2 micro-hardness and residual stress analyses are presented. Microhardness measurements are conducted beneath the machined surface. X-ray diffraction analysis is performed to obtain the residual stress distribution beneath the surface. Analytically, a 3-D thermo-elasto-plastic finite element model is developed to predict the residual stresses induced in the workpiece surface. In the model the cutting zone is specified based on the tool condition (i.e., sharp or worn). The finite element analysis demonstrates the significant effect of the heat generated during cutting on the residual stress distribution. The results illustrate the possibility of minimizing the high tensile residual stresses produced in the workpiece surface, by selecting the appropriate depth of cut. A good correlation between the analytical and predicted residual stress is obtained. [S1087-1357(00)00804-2]

Residual Stress Profiles of the Laser Surface Remelted Nodular Irons

2005 ◽  
Vol 490-491 ◽  
pp. 460-468 ◽  
Author(s):  
Janez Grum ◽  
Roman Šturm
Keyword(s):  
Residual Stress ◽  
Surface Layer ◽  
Residual Stresses ◽  
Laser Beam ◽  
Stress Measurement ◽  
Laser Surface ◽  
Laser Remelting ◽  
Volume Changes ◽  
Workpiece Surface ◽  
Laser Surface Remelting

Laser remelting process is a very promising hardening method for ferrous and nonferrous alloys, which do not show a homogeneous microstructural state after having been heattreated in a traditional way. Consequently, the alloys concerned do not achieve the required hardness of the surface layer and do not provide the required wear resistance either. The paper deals with residual stresses of thin flat specimens of nodular cast iron 500-7 in the laser remelting process. In the process of gradual remelting of the specimen surface, that is during its heating and cooling, volume changes of the specimen occur due to thermal and microstructural changes. For a better knowledge of volume changes in the thin surface layer of the specimen, the latter were evaluated by residual-stress measurement in the thin modified surface layer after the remelting process. In laser remelting of a workpiece such remelting conditions should be ensured that a uniform thickness of the modified layer could be obtained in spite of several laser-beam passages across the workpiece surface. Because of a multiple laser-beam passage across the workpiece surface, the state of internal stress in the workpiece changes. Optimal laser surface remelting conditions on the basis of knowing the residual stresses were chosen, while the way of guiding the laser beam over the surface of flat samples and degree of overlapping were varied.

Sign in / Sign up

Export Citation Format

Share Document