A Finite Element Analysis Based Compliance Method Coupled With Wet Etching to Determine Residual Stress in High Speed Milling

2005 ◽  
Author(s):  
S. C. Ammula ◽  
Y. B. Guo ◽  
M. E. Barkey
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
High Speed ◽  
Wet Etching ◽  
Cutting Conditions ◽  
Traditional Methods ◽  
New Approach ◽  
High Speed Milling ◽  
Compliance Function

High speed milling (HSM) is widely used in automotive and aerospace industries in fabricating mechanical components from high strength aluminum and other alloys due to high productivity and good surface finish. HSM induced residual stresses may significantly impact the fatigue life and corrosion resistance of the machined components. Traditional methods of residual stress (RS) measurement, such as hole drilling, X-ray diffraction, and neutron diffraction, are very time consuming and expensive, especially for the shallow subsurface (usually <100 μm) of a machined component. The compliance method provides a convenient alternative to these approaches to determine the residual stress distributions in the subsurface. However, the compliance method using wire EDM is prone to experimental errors. In addition, the traditional approach to calculate compliance function is very complex. This paper presents a new wet etching approach to obtain strains as a function of slot depth introduced in the subsurface. The strain readings were collected from a strain gauge mounted on the specimen surface near the slot edge. The compliance function can be conveniently calculated by simulating slot cutting using the finite element method via a Legendre polynomial subroutine as the applied load. These calculated compliance functions and measured strain values at different depths were used as inputs into a program to calculate residual stress. This leads to much a faster and less expensive method of determining residual stresses when compared with the traditional methods of residual stress determination. The capability of this new approach was demonstrated by high speed milling 6061-T651 and 7050-T7451 aluminum alloys. A design of experiment (DOE) method was adopted to conduct fifty-four cutting conditions with three levels of cutting speed, feed rate, and depth of cut. Residual stress profiles with twelve data points with spatial resolution as small as 1 μm in the subsurface were then obtained using this new approach. Residual stress sensitivity to cutting conditions was investigated. In addition, subsurface microstructure and microhardness were characterized.

A Wet Etching Method Coupled With Finite Element Analysis-Based Compliance Function to Determine Residual Stress in High-Speed Milling

2006 ◽  
Vol 128 (3) ◽  
pp. 792-801 ◽  
Author(s):  
Y. B. Guo ◽  
S. C. Ammula ◽  
M. E. Barkey
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
High Speed ◽  
Stress Measurement ◽  
Cutting Speed ◽  
Wet Etching ◽  
Traditional Methods ◽  
Element Analysis ◽  
High Speed Milling ◽  
Compliance Function

High-speed milling (HSM) is widely used in the automotive and aerospace industries in fabricating mechanical components. HSM induced residual stress may significantly impact fatigue life and the corrosion resistance of machined components. Traditional methods of residual stress measurement are very time consuming and expensive. In this paper we presents a wet etching approach to obtain strain as a function of slot depth introduced in the subsurface. The strain readings were collected from a strain gauge mounted on the specimen surface near the slot edge. A compliance function can be conveniently calculated by simulating slot cutting using a finite element method via a Legendre polynomial subroutine as the applied load. The calculated compliance functions and measured strain values at different depths were used as inputs into a program to calculate residual stress. This leads to a faster and less expensive method of determining residual stress when compared with the traditional methods. The capability of this new approach was demonstrated by high-speed milling 6061-T651 and 7050-T7451 aluminum alloys. A design-of-experiment method was used to conduct milling tests with three levels of cutting speed, feed rate, and DOC. Residual stress profiles with 12 data points with the spatial resolution as small as 1μm in the subsurface were then obtained. Residual stress sensitivity to cutting conditions was investigated. In addition, subsurface microstructure and microhardness were also measured to characterize surface integrity in a broad sense.

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.

Effect of the Welding Heat Input on Residual Stresses in Butt-Weld of High-Speed Train

2011 ◽  
Vol 337 ◽  
pp. 255-261 ◽  
Author(s):  
Zhong Yin Zhu ◽  
Peng Chen ◽  
Hong Mei Zhou ◽  
Yong Hui Zhu ◽  
Yong Hong Chen ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Heat Input ◽  
High Speed ◽  
Side Wall ◽  
High Speed Train ◽  
Butt Weld ◽  
Car Body ◽  
Welding Heat Input

Abstract. This study used finite element software SYSWELD to analyze residual stresses in butt-weld between underframe and side wall of high-speed train car body. Based on the thermal-elastic-plastic theory, double ellipsoid heat source model is adopted to simulate the residual stresses under different heat input in the welded joints between underframe and side wall. The residual stresses at the surface of weld specimen were measured experimentally by using the hole-drilling method. The results of the finite element analysis were compared with experimentally measured data to evaluate the accuracy of the finite element modeling. Based on this study, a modelling procedure with reasonable accuracy was developed. The developed finite element modelling was used to study the effects of welding heat input on magnitude and distribution of welding residual stresses in butt-weld of high-speed train car body made of A6N01-T5. The results show the maximum residual stress exists in the welded seam and the adjacent-weld zone, and the residual stress value decreases gradually while the zone is farther from the weld center .Besides, With the increase of the welding heat input, the residual stress value increases gradually.

Effect Residual Stress on Material Hardness by Finite Element Simulation during the Process of High Speed Cutting

2016 ◽  
Vol 719 ◽  
pp. 23-27
Author(s):  
De Weng Tang ◽  
Zhi Feng He ◽  
Xi Jian Lv ◽  
Cong Peng
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
High Speed ◽  
Cutting Temperature ◽  
Element Model ◽  
Residual Tensile Stress ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Material Hardness

Residual stresses induced during the process of high speed cutting are very critical due to safety and corrosion resistance. Based on the nonlinear finite element code DEFORM, thermodynamic couple model of residual stress was built. Effect distribution of residual stresses on three different materials physical properties of hardness are analyzed by using the finite element model during the process of high speed cutting. The results show that metal material hardness is the key factors to residual stress. When materials’ hardness is higher, residual tensile stress is easy to form on the machined surface due to high cutting temperature, such as hardened steel SKD11(HRC=62). To lower hardness material, residual compressive stress is generated on the machined surface for plastic deformation, such as softer materials 7075Al (HRC=23).

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]

Finite Element Analysis of Residual Stresses in High-Speed Dry Cutting of Biodegradable Magnesium-Calcium Alloy

2012 ◽  
Author(s):  
M. Salahshoor ◽  
Y. B. Guo
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Material Behavior ◽  
Human Anatomy ◽  
Dry Cutting ◽  
Stress Profiles ◽  
Cutting Regimes

Magnesium-Calcium (Mg-Ca) alloys have become attractive biodegradable orthopedic implant biomaterials recently. Residual stresses are proven to be very influential on degradation rate of these alloys in human anatomy. Due to time and cost inhibitive reasons, development of finite element models to predict residual stress profiles under various cutting regimes is highly desirable. In this context, a finite element model of orthogonal cutting without explicit chip formation is developed by adopting plowing depth approach in order to predict process induced residual stresses in high speed dry cutting of Mg-Ca0.8 (wt %) using diamond tools. Mechanical properties of Mg-Ca0.8 alloy at high strain rates and large strains are determined using split-Hopkinson pressure bar test. Internal state variable (ISV) plasticity model is implemented to model the material behavior under cutting regimes. The residual stress evolution process and effects of plowing speed and plowing depth on residual stress profiles are studied. Residual stress measurements are performed utilizing X-ray diffraction technique for validation purposes.

scholarly journals A New Approach for the Control and Reduction of Warpage and Residual Stresses in Bonded Wafer

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 361
Author(s):  
Seyed Amir Fouad Farshchi Yazdi ◽  
Matteo Garavaglia ◽  
Aldo Ghisi ◽  
and Alberto Corigliano
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Modeling ◽  
Glass Frit ◽  
Silicon Wafers ◽  
Bonding Process ◽  
New Approach ◽  
Curvature Variation ◽  
Out Of Plane

A geometrical modification on silicon wafers before the bonding process, aimed to decrease (1) the residual stress caused by glass frit bonding, is proposed. Finite element modeling showed that (2) by introducing this modification, the wafer out-of-plane deflection was decreased by 34%. Moreover, (3) fabricated wafers with the proposed geometrical feature demonstrated an improvement for the (4) warpage with respect to the plain wafers. A benefit for curvature variation and overall shape of the (5) bonded wafers was also observed.

scholarly journals Residual Stress Measurements in Mo/CuCrZr Tiles Using Neutron Diffraction

2008 ◽  
Vol 59 ◽  
pp. 299-303
Author(s):  
K. Mergia ◽  
Marco Grattarola ◽  
S. Messoloras ◽  
Carlo Gualco ◽  
Michael Hofmann
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Heat Sink ◽  
High Yield ◽  
Fusion Reactors ◽  
Plasma Facing Components ◽  
Induced Stresses ◽  
Compliant Layer

In plasma facing components (PFC) for nuclear fusion reactors tungsten or carbon based tiles need to be cooled through a heat sink. The joint between the PFC and the heat sink can be realized using a brazing process through the employment of compliant layer of either a low yield material, like copper, or a high yield material, like molybdenum. Experimental verification of the induced stresses during the brazing process is of vital importance. Strains and residual stresses have been measured in Mo/CuCrZr brazed tiles using neutron diffraction. The strains and stresses were measured in Mo tile along the weld direction and at different distances from it. The experimental results are compared with Finite Element Simulations.

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