Residual Thermal Stresses Simulation of Television Panel in the Forming Process. Part 1: Modelling

2006 ◽  
Vol 220 (5) ◽  
pp. 573-582 ◽  
Author(s):  
H. M. Zhou ◽  
G. D. Xi ◽  
D. Q. Li
Keyword(s):  
Residual Stresses ◽  
Thermal Stresses ◽  
Computational Cost ◽  
Material Model ◽  
Thermomechanical Properties ◽  
Shift Function ◽  
Layer By Layer ◽  
Parallel Plates ◽  
Forming Process ◽  
Molten Layer

Internal residual stresses in glass-pressed components such as television panel are mainly frozen in thermal stresses because of inhomogeneous cooling when surface layers stiffen sooner than the core region as in free quenching. Additional factors in pressing are the effects of melt pressure history and mechanical restraints of the mould. The solidification of a molten layer of glass between cooled parallel plates is used to model the mechanics of the buildup of residual stresses in the pressing process. Flow effects are neglected, and a thermorheologically simple thermoviscoelastic material model is assumed. The equilibrium thermomechanical properties of the material and the shift function can be temperature- and pressure-dependent. The finite-element method employed in the numerical simulation is based on the theory of shells, as an assembly of flat elements. The approach allows the prediction of residual deformations and residual stresses layer by layer like a truly three-dimensional calculation while reducing the computational cost significantly.

Elasto-Plastic Analysis of Thermal Stress Development During VAR of Ingots

1999 ◽  
Author(s):  
M. K. Alam ◽  
K. K. Wong ◽  
S. L. Semiatin
Keyword(s):  
Thermal Stresses ◽  
Plastic Material ◽  
Material Model ◽  
Thermomechanical Properties ◽  
Vacuum Arc ◽  
Aerospace Materials ◽  
Temperature Dependent ◽  
Vacuum Arc Remelting ◽  
High Cooling Rates ◽  
Dc Arc

Abstract The vacuum arc remelting (VAR) process has been developed to melt and cast high quality aerospace materials such as titanium alloys. VAR comprises the continuous remelting of a consumable electrode by means of a dc arc under vacuum or a low partial pressure of argon. The molten metal solidifies in a water-cooled copper crucible leading to high cooling rates that often results in large thermal stresses. The development of temperature gradients and the resulting thermal stresses during the VAR processes was investigated using an elasto-plastic material model with temperature dependent thermomechanical properties. Detailed solutions were obtained by using the commercial finite element code ABAQUS.

Modeling and Simulation of Shrinkage During the Picture Tube Panel Forming Process

2006 ◽  
Vol 129 (2) ◽  
pp. 380-387 ◽  
Author(s):  
Huamin Zhou ◽  
GuoDong Xi ◽  
Dequn Li
Keyword(s):  
Residual Stresses ◽  
Dimensional Accuracy ◽  
Relaxation Effect ◽  
Material Model ◽  
Forming Process ◽  
Molded Parts ◽  
Triangular Elements ◽  
Simulation Results ◽  
Residual Stress Analysis ◽  
Theory Of Shells

The accurate prediction of residual stresses and shrinkage of the formed picture tube panel is important to achieve high quality and precision of the final product. In this paper, the numerical simulation of shrinkage of molded panels was carried out in consideration of the residual stresses accumulated during both the packing and free-to-contract stages. For residual stress analysis, a thermorheologically simple viscoelastic material model was introduced to consider the stresses relaxation effect and to describe the mechanical behavior according to the temperature change. The deformation of molded parts induced by the residual stresses was calculated based on the theory of shells, represented as an assembly of flat elements formed by combining the constant strain and the discrete Kirchhoff triangular elements. The simulation results of the developed program were side verified by comparing the dimensional accuracy of the panels produced by the molds, which compensated for a uniform part shrinkage or the predicted ununiform part shrinkage.

scholarly journals Model Of Relaxation Of Residual Stresses In Hot-Rolled Strips

2015 ◽  
Vol 60 (3) ◽  
pp. 1935-1940 ◽  
Author(s):  
A. Milenin ◽  
R. Kuziak ◽  
V. Pidvysots'kyy ◽  
P. Kustra ◽  
Sz. Witek ◽  
...  
Keyword(s):  
Stress Relaxation ◽  
Residual Stresses ◽  
Thermal Stresses ◽  
Plastic Material ◽  
Material Model ◽  
Creep Model ◽  
Creep Theory ◽  
Elastic Plastic ◽  
Elastic Plastic Material ◽  
Hot Rolled

Abstract Residual stresses in hot-rolled strips are of practical importance when the laser cutting of these strip is applied. The factors influencing the residual stresses include the non uniform distribution of elastic-plastic deformations, phase transformation occurring during cooling and stress relaxation during rolling and cooling. The latter factor, despite its significant effect on the residual stress, is scarcely considered in the scientific literature. The goal of the present study was development of a model of residual stresses in hot-rolled strips based on the elastic-plastic material model, taking into account the stress relaxation. Residual stresses in hot-rolled strips were evaluated using the FEM model for cooling in the laminar cooling line and in the coil. Relaxation of thermal stresses was considered based on the creep theory. Coefficients of elastic-plastic material model and of the creep model for steels S235 and S355 were obtained from the experiments performed on the Gleeble 3800 simulator for the temperatures 35-1100°C. Experiments composed small tensile deformations of the sample (0.01-0.02) and subsequent shutter speed without removing the load. Model of the thermal deformation during cooling was obtained on the basis of the dilatometric tests at cooling rates of 0.057°C/s to 60°C/s. Physical simulations of the cooling process were performed to validate the model. Samples were fixed in the simulator Gleeble 3800, then heated to the temperature of 1200°C and cooled to the room temperature at a rate of 1-50°C/s. Changes of stresses were recorded. Good agreement between calculated and experimental values of stresses was observed. However, due to neglecting the effect of stress relaxation the stress at high temperatures was overestimated. Due to the change of their stress sign during the unloading process the resulting residual stresses were underestimated. Simulation of residual stresses in rolling and cooling were performed on the basis of the developed model. It was shown that the effect of stress relaxation and phase transformations on the distribution of residual stresses in strips is essential and neglecting these factors could lead to an underestimation of residual stresses.

Residual Thermal Stresses Simulation of Television Panel in the Forming Process. Part 2: Simulations and Validation

2006 ◽  
Vol 220 (5) ◽  
pp. 583-591 ◽  
Author(s):  
H. M. Zhou ◽  
W Feng ◽  
T Geng ◽  
D. Q. Li
Keyword(s):  
Residual Stresses ◽  
Thermal Stresses ◽  
Temperature History ◽  
Experimental Comparison ◽  
Maximum Deviation ◽  
Specimen Thickness ◽  
Forming Process ◽  
Thermographic Camera ◽  
Analysis System ◽  
Impinging Cooling

To obtain the temperature history data of the part taken for residual stresses analysis, a numerical simulation has been developed for the part cooling during the TV panel forming process. In the simulation, a local one-dimensional transient analysis in the thickness direction is adopted, which employs the finite-difference method. The renormalization-group turbulence model is applied for jet impinging cooling. By applying the numerical analysis system described in Part I, the residual stresses in the formed TV panel part are predicted. Experimental comparison is employed to verify the proposed models and methods. The temperatures were measured by a thermographic camera and the residual stresses were measured using the birefringence. On the whole, the predictions are encouraging. The agreement between measured temperatures and simulation results is very good, with the maximum deviation within 5 per cent. The residual stresses trends of the experimental results indicated a similar behaviour over most of specimen thickness. Also, the results showed about the same magnitude of predicted stresses in specimen.

scholarly journals Mechanical properties of rotary swaged steel components

2021 ◽  
Author(s):  
Dhia Charni ◽  
Svetlana Ortmann-Ishkina ◽  
Marius Herrmann ◽  
Christian Schenck ◽  
Jérémy Epp
Keyword(s):  
Mechanical Properties ◽  
Residual Stresses ◽  
Strain Curve ◽  
Dynamic Mechanical Properties ◽  
Process Conditions ◽  
Forming Process ◽  
Rotary Swaging ◽  
Surface Residual Stresses ◽  
Near Net Shape ◽  
As Stress

AbstractThe radial infeed rotary swaging is widely used as a diameter reduction forming process of axisymmetric workpieces, improving the mechanical properties with excellent near net shape forming. In the present study, rotary swaging experiments with different parameter setups were performed on steel tubes and bars under different material states and several resulting property modifications were investigated such as stress-strain curve, hardness, fatigue strength and surface residual stresses. The results show a significant work hardening induced by the rotary swaging process and an improvement in the static and dynamic mechanical properties was observed. Furthermore, the hardness distribution was homogenous in the cross section of the rotary swaged workpieces. Moreover, depending on the process conditions, different residual stresses distribution were generated along the surface.

Localization simulation of forming-induced residual stresses of composite using prescribed boundary

2021 ◽  
pp. 073168442094118
Author(s):  
Qi Wu ◽  
Hongzhou Zhai ◽  
Nobuhiro Yoshikawa ◽  
Tomotaka Ogasawara ◽  
Naoki Morita
Keyword(s):  
Residual Stresses ◽  
Representative Volume Element ◽  
Computational Cost ◽  
Volume Element ◽  
Thermoplastic Composite ◽  
Structural Deformation ◽  
Element Analysis ◽  
Micro Scale ◽  
Representative Volume ◽  
Localization Approach

A novel localization approach that seamlessly bridges the macro- and micro-scale models is proposed and used to model the forming-induced residual stresses within a representative volume element of a fiber reinforced composite. The approach uses a prescribed boundary that is theoretically deduced by integrating the asymptotic expansion of a composite and the equal strain transfer, thus rendering the simulation setting to be easier than conventional approaches. When the localization approach is used for the finite element analysis, the temperature and residual stresses within an ideal cubic representative volume element are precisely simulated, given a sandwiched thermoplastic composite is formed under one-side cooling condition. The simulation results, after being validated, show that the temperature gradient has an impact on the local residual stresses, especially on the in-plane normal stress transverse to the fiber, and consequently, influences the structural deformation. This newly designed localization approach demonstrates the advantages of enhanced precision and reduced computational cost owing to the fast modeling of the finely meshed representative volume element. This is beneficial for a detailed understanding of the actual residual stresses at the micro-scale.

Wrinkling Prediction and Optimization of Sheet Metal Forming Process by Numerical Simulation

2015 ◽  
Vol 818 ◽  
pp. 252-255 ◽  
Author(s):  
Ján Slota ◽  
Marek Šiser
Keyword(s):  
Numerical Simulation ◽  
Material Model ◽  
Mechanical Tests ◽  
Simulation Software ◽  
Forming Process ◽  
Part Geometry ◽  
Nominal Thickness ◽  
430 Stainless Steel ◽  
Metal Forming Process ◽  
Aisi 430

The paper deals with optimization of forming process for AISI 430 stainless steel with nominal thickness 0.4 mm. During forming of sidewall for washing machine drum, some wrinkles remain at the end of forming process in some places. This problem was solved by optimization the geometry of the drawpiece using numerical simulation. During optimization a series of modifications of the part geometry to absolute elimination of wrinkling was performed. On the basis of mechanical tests, the material model was created and imported into the material database of Autoform simulation software.

Influence of Phase Transformations on Residual Stresses in Welded Structures

2013 ◽  
Author(s):  
R. J. Dennis ◽  
R. Kulka ◽  
O. Muransky ◽  
M. C. Smith
Keyword(s):  
Phase Transformation ◽  
Residual Stresses ◽  
Phase Transformations ◽  
Numerical Models ◽  
Material Model ◽  
Transformation Model ◽  
Austenitic Steels ◽  
Beam Specimen ◽  
Welded Structures ◽  
The Impact

A key aspect of any numerical simulation to predict welding induced residual stresses is the development and application of an appropriate material model. Often significant effort is expended characterising the thermal, physical and hardening properties including complex phenomena such as high temperature annealing. Consideration of these aspects is sufficient to produce a realistic prediction for austenitic steels, however ferritic steels are susceptible to solid state phase transformations when heated to high temperatures. On cooling a reverse transformation occurs, with an associated volume change at the isothermal transformation temperature. Although numerical models exist (e.g. Leblond) to predict the evolution of the metallurgical phases, accounting for volumetric changes, it remains a matter of debate as to the magnitude of the impact of phase transformations on residual stresses. Often phase transformations are neglected entirely. In this work a simple phase transformation model is applied to a range of welded structures with the specific aim of assessing the impact, or otherwise, of phase transformations on the magnitude and distribution of predicted residual stresses. The welded structures considered account for a range of geometries from a simple ferritic beam specimen to a thick section multi-pass weld. The outcome of this work is an improved understanding of the role of phase transformation on residual stresses and an appreciation of the circumstances in which it should be considered.

DESTRUCTIVE METHODS FOR DETERMINING RESIDUAL STRESSES (review)

2021 ◽  
pp. 95-104
Author(s):  
A.D. Monakhov ◽  
◽  
N.O. Yakovlev ◽  
V.V. Avtaev ◽  
E.A. Kotova ◽  
...  
Keyword(s):  
Digital Image Correlation ◽  
Residual Stresses ◽  
Speckle Interferometry ◽  
Image Correlation ◽  
Strain Gauges ◽  
Contact Method ◽  
Layer By Layer ◽  
Deep Hole ◽  
Destructive Methods

The paper presents an overview of methods for determining residual stresses. Methods such as splitting and segmentation, layer-by-layer removal, slitting (cutting, pliability), profiling, drilling holes (including a «deep» hole) are considered. The description of the methods for mea-suring the deformation used in the determination of residual stresses is given. The most common contact method using strain gauges, as well as non-contact methods: polarization-optical (photo-elasticity), optical speckle interferometry, digital image correlation.

PREDICTION OF PEEK RESIN PROPERTIES FOR PROCESSING MODELING USING MOLECULAR DYNAMICS

2021 ◽  
Author(s):  
KHATEREH KASHMARI ◽  
PRATHAMESH DESHPANDE ◽  
SAGAR PATIL ◽  
SAGAR SHAH ◽  
MARIANNA MAIARU ◽  
...  
Keyword(s):  
Molecular Dynamics ◽  
Residual Stresses ◽  
Crystallization Kinetics ◽  
Material Properties ◽  
Elevated Temperatures ◽  
Processing Parameters ◽  
Thermomechanical Properties ◽  
Volumetric Shrinkage ◽  
Processing Temperature ◽  
Wide Range

Polymer Matrix Composites (PMCs) have been the subject of many recent studies due to their outstanding characteristics. For the processing of PMCs, a wide range of elevated temperatures is typically applied to the material, leading to the development of internal residual stresses during the final cool-down step. These residual stresses may lead to net shape deformations or internal damage. Also, volumetric shrinkage, and thus additional residual stresses, could be created during crystallization of the semi-crystalline thermoplastic matrix. Furthermore, the thermomechanical properties of semi-crystalline polymers are susceptible to the crystallinity content, which is tightly controlled by the processing parameters (processing temperature, temperature holding time) and material properties (melting and crystallization temperatures). Hence, it is vital to have a precise understanding of crystallization kinetics and its impact on the final component's performance to accurately predict induced residual stresses during the processing of these materials. To enable multi-scale process modeling of thermoplastic composites, molecular-level material properties must be determined for a wide range of crystallinity levels. In this study, the thermomechanical properties and volumetric shrinkage of the thermoplastic Poly Ether Ether Ketone (PEEK) resin are predicted as a function of crystallinity content and temperature using molecular dynamics (MD) modeling. Using crystallization-kinetics models, the thermo-mechanical properties are directly related to processing time and temperature. This research can ultimately predict the residual stress evolution in PEEK composites as a function of processing parameters.

Sign in / Sign up

Export Citation Format

Share Document