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.

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.

scholarly journals Effect of a Multiple Reduction Die on the Residual Stress of Drawn Materials

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1358
Author(s):  
Jeong-Hun Kim ◽  
Chang-Hyun Baek ◽  
Sang-Kon Lee ◽  
Jong-Hun Kang ◽  
Joon-Hong Park ◽  
...  
Keyword(s):  
Neural Network ◽  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Deep Neural Network ◽  
Drawing Process ◽  
X Ray Diffraction ◽  
Element Analysis ◽  
X Ray

Residual stress may influence the mechanical behavior and durability of drawn materials. Thus, this study develops a multiple reduction die (MRD) that can reduce residual stress during the drawing process. The MRD set consists of several die tips, die cases, and lubricating equipment. All the die tips of the MRD were disposed of simultaneously. Finite element analysis of the drawing process was performed according to the reduction ratio of each die tip, and the variables in drawing process with the MRD were optimized using a deep neural network to minimize the residual stress. Experiments on the drawing process with the conventional die and MRD were performed to evaluate the residual stress and verify the effectiveness of the MRD. The results of X-ray diffraction measurements indicated that the axial and hoop residual stresses on the surface were dramatically reduced.

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.

Three-Dimensional Finite Element Analysis of the Cold Expansion of Fastener Holes in Two Aluminum Alloys

2002 ◽  
Vol 124 (2) ◽  
pp. 140-145 ◽  
Author(s):  
Jidong Kang ◽  
W. Steven Johnson ◽  
David A. Clark
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloys ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Element Analysis ◽  
Hardening Models ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

A three-dimensional finite element analysis is developed for the cold expansion process in two aluminum alloys, 2024-T351 and 7050-T7451. The entire cold working process including hole expansion, elastic recovery, and finish reaming is simulated. Both isotropic hardening and kinematic hardening models are considered in the numerical calculations. The results suggest that a three-dimensional nature exists in the residual stress fields surrounding the hole. There are significant differences in residual stresses at different sections through the thickness. However, residual stress at the surface is shown to remain the same for the different plastic hardening models after the hole has recovered and finish reaming has been performed. The reaming of the material around the hole has slight effect on the maximum value and distribution of residual stresses. A comparison has been drawn between the FEA of average through thickness strain and a previous experimental investigation of strain that utilized neutron diffraction and modified Sachs boring on a 7050 aluminum specimen containing a cold expanded hole. The different methods show very good agreement in the magnitude of strain as well as the general trend. The conclusions obtained here are beneficial to the understanding of the phenomenon of fatigue crack initiation and growth at the perimeter of cold worked holes.

Finite Element Analysis of the Effect of Oil Jet Peening Process in a Material

2009 ◽  
Author(s):  
A. Sahaya Grinspon ◽  
R. Gnanamoorthy
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Element Analysis ◽  
Stress Components ◽  
Modification Technique ◽  
Loading And Unloading ◽  
Oil Jet ◽  
The Impact

Oil peening is a new surface modification technique developed to introduce compressive residual stresses in metallic components. The magnitude and distribution of residual stresses and plastic strain in the oil peened AA6061-T4 alloy was evaluated using finite element method (FEM). The simulation of single drop impact against a plastically deformable material was performed. The contours of stress components are presented to show the formation of residual stress distribution. Finite element analysis reveals that the stress and strain patterns around the impact region of an oil drop during loading and unloading with different impact pressures. Impact pressure significantly influences the axial displacement, residual pileup and residual stress.

Three-Dimensional Transient Residual Stress Finite Element Analysis for a Laser Clad Surface

2003 ◽  
Author(s):  
S. Ghosh ◽  
J. Choi
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Phase Transformation ◽  
Residual Stresses ◽  
Material Behavior ◽  
Heat Transfer Analysis ◽  
Transformation Kinetics ◽  
Element Analysis ◽  
Phase Transformation Kinetics

Laser aided manufacturing process inherently includes many nonlinear and non-equilibrium transport phenomena due to non-uniform and rapid heat flow caused by the laser and the material interaction. Comprehensive understanding of the transport phenomenon and heat transfer analysis including phase transformation is essential to predict the effects of thermally induced residual stresses and distortions in deposited materials. It not only helps to improve the process but also reduces the long and cumbersome experimental route to compile sufficient data to predict the material behavior under similar loading conditions. This paper is an attempt towards a methodology of finite element analysis for the prediction of quenching related macroscopic as well as microscopic residual stress in a laser cladding process. A finite element program has been written to account for the micro-residual stress effects. The program is essentially a coupling between a preliminary estimation of temperature history of the system and the final prediction of residual stresses which also include the phase transformation kinetics of the material during its cooling. The importance of considering phase transformation effects during quenching is also verified through the comparison of the magnitudes of residual stresses with and without the inclusion of phase transformation kinetics. The FEA program for this model is a very useful tool for designing and optimizing Laseraided Direct Metal Deposition (DMD) process conditions so that products with the best internal quality and dimensional accuracy can be built.

Residual Stress Analysis in Shot Peened and Fretting Fatigued Samples by the Eigenstrain Method

2006 ◽  
Vol 524-525 ◽  
pp. 343-348 ◽  
Author(s):  
Alexander M. Korsunsky ◽  
Kyung Mok Kim ◽  
Gabriel M. Regino
Keyword(s):  
Experimental Data ◽  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Fatigue Loading ◽  
Element Model ◽  
Fretting Fatigue ◽  
X Ray Diffraction ◽  
Element Analysis

Residual stresses in titanium alloy samples that were subjected to shot peening followed by fretting fatigue loading were investigated using a combined experimental and numerical analysis procedure based on the concept of eigenstrain. Fretting fatigue loading was carried out in the pad – on-flat geometry using the Oxford in-line fretting rig. Flat-and-rounded pad shape was used to introduce the contact tractions and internal stress fields typical of the target application in aeroengine design. The specimens were in the shape of bars of 10mm square cross-section shotpeened on all sides. Both the pads and specimens were made from the Ti-6Al-4V alloy. Small remote displacement characteristic of fretting fatigue conditions was applied in the experiments. The residual elastic strains in the middle of the pad-to-sample contact and near the rounded pad edge were measured using synchrotron X-ray diffraction on Station 16.3 at SRS Daresbury. A combination of finite element analysis and the distributed eigenstrain method was used in the simulations. Commercial finite element analysis software, ABAQUS ver 6.41, was used to build the finite element model and to introduce the residual stresses into the model using eigenstrain distributions via a user-defined subroutine. In an unfretted shot peened sample an excellent agreement of residual stress profiles was obtained between the experimental data and model prediction by the variational eigenstrain procedure. In a fretted sample the residual stress change due to fretting was observed, and predicted numerically. A good correlation was found between the FE simulation prediction and the experimental data measured at contact edges.

Finite Element Analysis of Residual Stresses in Butt Welding of Stainless Steel Plates by GTAW

2010 ◽  
Author(s):  
Gurinder Singh Brar ◽  
Rakesh Kumar
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Stainless Steel ◽  
Residual Stresses ◽  
304 Stainless Steel ◽  
Aisi 304 Stainless Steel ◽  
Element Analysis ◽  
Aisi 304 ◽  
Butt Welding

Welding is one of the most commonly used permanent joining processes in the piping and pressure vessel industry. During welding a very complex thermal cycle is applied to the weldment, which in turn causes irreversible elastic-plastic deformation and consequently gives rise to the residual stresses in and around fusion zone and heat affected zone (HAZ). Presence of residual stresses may be beneficial or harmful for the structural components depending on the nature and magnitude of stresses. The beneficial effect of compressive stresses have been widely used in industry as these are believed to increase fatigue strength of the component and reduce stress corrosion cracking and brittle fracture. In large steel fabrication industries such as shipbuilding, marine structures, aero-space industry, high speed train guide ways and pressure vessels and piping in chemical and petrochemical industry the problem of residual stresses and overall distortion has been and continue to be a major issue. It is well established fact that material response of structural components is substantially affected by the residual stresses when subjected to thermal and structural loads. Due to these residual stresses produced in and around the weld zone the strength and life of the component is reduced. As AISI 304 stainless steel has excellent properties like better corrosion resistance, high ductility, excellent drawing, forming and spinning properties, so it is almost used in all types of application like chemical equipment, flatware utensils, coal hopper, kitchen sinks, marine equipment etc. But because of the problems of residual stresses during the time of welding it is very essential to understand the behavior and nature of AISI 304 stainless steel material. So in order to overcome all these problems a 3-dimensional finite element model is developed in a commercially available FEA code by drafting an approximate geometry of the butt welded joint and then the finite element analysis is performed, so that one can understand the complete nature of residual stresses in butt welding of AISI 304 stainless steel plate. In this paper, butt welding simulations were performed on two AISI 304 stainless steel plates by gas tungsten arc welding (GTAW). Analysis of butt welded joint by commercially available finite element analysis code showed that butt weld produced by GTAW resulted in 782.84 MPa of residual stress in plates. In addition, the residual stress is plotted against axial distance to have a clear picture of the magnitude of residual stress in and around weld area.

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