Numerical approaches and experimental verification of the conical indentation techniques for residual stress evaluation

2010 ◽  
Vol 25 (11) ◽  
pp. 2212-2223 ◽  
Author(s):  
Jin Haeng Lee ◽  
Hyungyil Lee ◽  
Hong Chul Hyun ◽  
Minsoo Kim
Keyword(s):  
Residual Stress ◽  
Material Properties ◽  
Compressive Residual Stress ◽  
Plasticity Theory ◽  
Bending Stress ◽  
Stress Evaluation ◽  
Four Point Bending ◽  
Indentation Methods ◽  
Numerical Approaches ◽  
Conical Indentation

Conical indentation methods to determine residual stress are proposed by examining the finite element solutions based on the incremental plasticity theory. We first note that hardness depends on the magnitude and sign of residual stress and material properties and can change by up to 20% over a specific range of elastic tensile and compressive residual stress, although some prior indentation studies reported that hardness is hardly affected by residual stress. By analyzing the characteristics of conical indentation, we then select some normalized indentation parameters, which are free from the effect of indenter tip rounding. Adopting dimensional analysis, we present practical conical indentation methods for the evaluation of elastic/plastic equi- and nonequi-biaxial residual stresses. The validity of developed approaches is confirmed by applying them to the experimental evaluation of four-point bending stress.

An Indentation Method Based on FEA for Equi-Biaxial Residual Stress Evaluation

2006 ◽  
Vol 326-328 ◽  
pp. 481-486
Author(s):  
Jin Haeng Lee ◽  
Hyung Yil Lee
Keyword(s):  
Residual Stress ◽  
Material Properties ◽  
Plasticity Theory ◽  
Indentation Method ◽  
Stress Evaluation ◽  
New Approach ◽  
Normalized Parameters ◽  
Tip Radius

An indentation method to determine equi-biaxial residual stress is proposed by examining the data from the incremental plasticity theory based FE analyses. We found that hardness is strongly dependent of the magnitude and sign of residual stress and material properties. We then selected some normalized parameters minimally affected by material properties and tip radius. With numerical regressions of the data obtained, we proposed new formulae for residual stress evaluation. The new approach provides a substantial enhancement in accuracy compared with the prior methods.

scholarly journals Manufacturing Process beyond Conventional Plasticity Theory: Case Study in Manufacturing Low Spring Index Coil

2020 ◽  
Vol 1 (2) ◽  
pp. 98-104
Author(s):  
Yunan Prawoto ◽  
Sonia Manville ◽  
T Sakai ◽  
M Tanaka ◽  
T Gnauple-Herold
Keyword(s):  
Residual Stress ◽  
Fracture Mechanics ◽  
Material Properties ◽  
Manufacturing Process ◽  
Annealing Process ◽  
Plasticity Theory ◽  
Coil Spring ◽  
Academic World

In the academic world, conventional plasticity theory limits the cold process due to energy inefficiency, material properties and residual stress that may inhibit the quality of a product, and therefore usually not recommended. However, industrial competition pushes that limits against the edge. Knowing the consequences in advance helps reducing the damage that may have been caused by such a violation. This paper shows an example in the form of a case study. A coil spring with a very low spring index that academically suggested to be made using hot process was attempted to be manufactured using cold coiling machine. The case study shows that although it is possible, extra careful and timely handling must be done to successfully manufacture it. A coil with excessive residual stress is shown in this paper. That residual stress alone was capable in damaging the coil during manufacturing. The defect takes place after coiling and before tempering process. A fracture mechanics was used to analyze the failure, which is the splitting due to excessive residual stress. The case study also shows that the problem can be solved by speedy and subsequent stress relieve annealing process.

Study of Impact Velocity on Residual Stress and Surface Hardness of SKD11 in Shot Peening Process

2020 ◽  
Vol 304 ◽  
pp. 127-134
Author(s):  
Pudsadee Chupong ◽  
Karuna Tuchinda
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Impact Velocity ◽  
Process Parameters ◽  
Material Properties ◽  
Shot Peening ◽  
Compressive Residual Stress ◽  
Surface Hardness ◽  
Impact Angle ◽  
Residual Stress Distribution

Shot peening process could create compressive residual stress and increase surface hardness and hence also used to improve material surface properties in case thermal effect is to be avoided. The shot peening process parameters such as pressure which result in different shot impact velocity could affect the compressive residual stress distribution which results in different post-process material properties. The ability to understand and predict the effect of process parameters on stress distribution could be very useful to control and obtain material properties as required. In this work, a shot peening process commercially available locally was investigated. The residual stress distribution after shot peening of SKD11 was studied using the finite element (FE) technique. A single shot impact was simulated. A maximum velocity with a miximum impact angle was assumed. The computational predictions showed higher compressive residual stress developed with increasing shot velocity as expected due to higher impact energy. However, experimental results suggested that the process arrangement and machine control highly affect the properties of the material after process. The compressive residual stress and surface hardness obtained experimentally was almost unchanged with an increase in pressure from 0.35MPa to 0.6MPa. It was found that, due to machine arrangement, an increase in impact velocity at higher pressure was relatively small and did not observed in all effected area due to fixed arrangement of nozzle and samples. Hence, research results suggested that a detail computational methodology including the effect of unevent impact velocity and impact angle should be employed to increase the predictive ability of the FE model. The current work could be extended to include such effects with no major difficulty to develop useful information for the design of shot peening process for any specific machine and arrangement.

Residual Stress Evaluation In Austenitic Stainless Steel Butt Weld Joints By Ultrasonic Technique

1992 ◽  
Vol 25 (3) ◽  
pp. 130 ◽  
Author(s):  
P. Palanichamy ◽  
A. Joseph ◽  
K. V. Kasiviswanathan ◽  
D. K. Bhattacharya ◽  
Baldev Raj
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Ultrasonic Technique ◽  
Butt Weld ◽  
Stress Evaluation ◽  
Weld Joints

scholarly journals Numerical Investigation on the Ultimate Strength of Box Beams with Impact Damage

2020 ◽  
Author(s):  
Wei Xu ◽  
C. Guedes Soares
Keyword(s):  
Residual Stress ◽  
Ultimate Strength ◽  
Impact Damage ◽  
Ship Hulls ◽  
Four Point Bending ◽  
Impact Location ◽  
Box Beam ◽  
Box Beams ◽  
Fracture Damage ◽  
The Impact

AbstractThe objective of this paper is to study the residual ultimate strength of box beams with impact-induced damage, as a model of what may occur in ship hulls. The bottom and side plates of ship hulls can suffer denting or fracture damage due to grounding, collision and other contacts during the ship’s service life and these impact-induced damages could result in considerable strength degradation. Box beams are firstly subjected to impact loading and then four-point bending loading is imposed on the damaged structures to assess the residual strength using ANSYS/LS_DYNA. The ultimate moment and collapse modes are discussed considering the effect of impact location. The impact-induced deformation is introduced in the four-point bending simulation, and the impact-induced stress is included or not to determine the effect of residual stress and distortion after impact. It is shown that impact location has significant influence on the residual ultimate bending moment of the damaged box beam providing that the impact energy is kept constant. The collapse modes also change when the impactor strikes on different locations. Damaged hard corner and inclined neutral axes might explain the reduction of ultimate strength and diverse collapse modes. The residual stress in the box beam after impact may increase or decrease the ultimate strength depending on impact location.

Monitoring of mechanical properties of prestressed glass fiber epoxy composites over 12 months after fabrication

2021 ◽  
pp. 002199832110047
Author(s):  
Mahmoud Mohamed ◽  
Siddhartha Brahma ◽  
Haibin Ning ◽  
Selvum Pillay
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Flexural Strength ◽  
Compressive Residual Stress ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Epoxy Composites ◽  
Flexural Properties ◽  
Initial Increase ◽  
Fiber Volume

Fiber prestressing during matrix curing can significantly improve the mechanical properties of fiber-reinforced polymer composites. One primary reason behind this improvement is the generated compressive residual stress within the cured matrix, which impedes cracks initiation and propagation. However, the prestressing force might diminish progressively with time due to the creep of the compressed matrix and the relaxation of the tensioned fiber. As a result, the initial compressive residual stress and the acquired improvement in mechanical properties are prone to decline over time. Therefore, it is necessary to evaluate the mechanical properties of the prestressed composites as time proceeds. This study monitors the change in the tensile and flexural properties of unidirectional prestressed glass fiber reinforced epoxy composites over a period of 12 months after manufacturing. The composites were prepared using three different fiber volume fractions 25%, 30%, and 40%. The results of mechanical testing showed that the prestressed composites acquired an initial increase up to 29% in the tensile properties and up to 32% in the flexural properties compared to the non-prestressed counterparts. Throughout the 12 months of study, the initial increase in both tensile and flexural strength showed a progressive reduction. The loss ratio of the initial increase was observed to be inversely proportional to the fiber volume fraction. For the prestressed composites fabricated with 25%, 30%, and 40% fiber volume fraction, the initial increase in tensile and flexural strength dropped by 29%, 25%, and 17%, respectively and by 34%, 26%, and 21%, respectively at the end of the study. Approximately 50% of the total loss took place over the first month after the manufacture, while after the sixth month, the reduction in mechanical properties became insignificant. Tensile modulus started to show a very slight reduction after the fourth/sixth month, while the flexural modulus reduction was observed from the beginning. Although the prestressed composites displayed time-dependent losses, their long-term mechanical properties still outperformed the non-prestressed counterparts.

scholarly journals Influence of Preaging Temperature on the Indentation Strength of 3Y-TZP Aged in Ambient Atmosphere

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 2767
Author(s):  
Ki-Won Jeong ◽  
Jung-Suk Han ◽  
Gi-Uk Yang ◽  
Dae-Joon Kim
Keyword(s):  
Residual Stress ◽  
Phase Transformation ◽  
Low Temperature ◽  
Compressive Residual Stress ◽  
Yttria Stabilized Zirconia ◽  
Ambient Atmosphere ◽  
Aged Specimen ◽  
Stabilized Zirconia ◽  
M Phase ◽  
The Relationship

Yttria-stabilized zirconia (3Y-TZP) containing 0.25% Al2O3, which is resistant to low temperature degradation (LTD), was aged for 10 h at 130–220 °C in air. The aged specimens were subsequently indented at loads ranging from 9.8 to 490 N using a Vickers indenter. The influence of preaging temperature on the biaxial strength of the specimens was investigated to elucidate the relationship between the extent of LTD and the strength of zirconia restorations that underwent LTD. The indented strength of the specimens increased as the preaging temperature was increased higher than 160 °C, which was accompanied by extensive t-ZrO2 (t) to m-ZrO2 (m) and c-ZrO2 (c) to r-ZrO2 (r) phase transformations. The influence of preaging temperature on the indented strength was rationalized by the residual stresses raised by the t→m transformation and the reversal of tensile residual stress on the aged specimen surface due to the indentation. The results suggested that the longevity of restorations would not be deteriorated if the aged restorations retain compressive residual stress on the surface, which corresponds to the extent of t→m phase transformation less than 52% in ambient environment.

scholarly journals Impact of residual stress evoked by pyramidal embossing on the magnetic material properties of non-oriented electrical steel

2021 ◽  
Author(s):  
Ines Gilch ◽  
Tobias Neuwirth ◽  
Benedikt Schauerte ◽  
Nora Leuning ◽  
Simon Sebold ◽  
...  
Keyword(s):  
Magnetic Material ◽  
Residual Stress ◽  
Magnetic Flux ◽  
Material Properties ◽  
Electrical Steel ◽  
Maximum Energy ◽  
Material Behavior ◽  
Electrical Machine ◽  
Element Analysis ◽  
Steel Sheets

AbstractTargeted magnetic flux guidance in the rotor cross section of rotational electrical machines is crucial for the machine’s efficiency. Cutouts in the electrical steel sheets are integrated in the rotor sheets for magnetic flux guidance. These cutouts create thin structures in the rotor sheets which limit the maximum achievable rotational speed under centrifugal forces and the maximum energy density of the rotating electrical machine. In this paper, embossing-induced residual stress, employing the magneto-mechanical Villari effect, is studied as an innovative and alternative flux barrier design with negligible mechanical material deterioration. The overall objective is to replace cutouts by embossings, increasing the mechanical strength of the rotor. The identification of suitable embossing geometries, distributions and methodologies for the local introduction of residual stress is a major challenge. This paper examines finely distributed pyramidal embossings and their effect on the magnetic material behavior. The study is based on simulation and measurements of specimen with a single line of twenty embossing points performed with different punch forces. The magnetic material behavior is analyzed using neutron grating interferometry and a single sheet tester. Numerical examinations using finite element analysis and microhardness measurements provide a more detailed understanding of the interaction of residual stress distribution and magnetic material properties. The results reveal that residual stress induced by embossing affects magnetic material properties. Process parameters can be applied to adjust the magnetic material deterioration and the effect of magnetic flux guidance.

scholarly journals Additive Manufactured 316L Stainless-Steel Samples: Microstructure, Residual Stress and Corrosion Characteristics after Post-Processing

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 182
Author(s):  
Suvi Santa-aho ◽  
Mika Kiviluoma ◽  
Tuomas Jokiaho ◽  
Tejas Gundgire ◽  
Mari Honkanen ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Sample Surface ◽  
Post Processing ◽  
Magnesium Chloride Solution ◽  
Manufacturing Method ◽  
Four Point Bending ◽  
Traditional Manufacturing ◽  
Processing Steps ◽  
Compressive Residual Stresses

Additive manufacturing (AM) is a relatively new manufacturing method that can produce complex geometries and optimized shapes with less process steps. In addition to distinct microstructural features, residual stresses and their formation are also inherent to AM components. AM components require several post-processing steps before they are ready for use. To change the traditional manufacturing method to AM, comprehensive characterization is needed to verify the suitability of AM components. On very demanding corrosion atmospheres, the question is does AM lower or eliminate the risk of stress corrosion cracking (SCC) compared to welded 316L components? This work concentrates on post-processing and its influence on the microstructure and surface and subsurface residual stresses. The shot peening (SP) post-processing levelled out the residual stress differences, producing compressive residual stresses of more than −400 MPa in the AM samples and the effect exceeded an over 100 µm layer below the surface. Post-processing caused grain refinement and low-angle boundary formation on the sample surface layer and silicon carbide (SiC) residue adhesion, which should be taken into account when using the components. Immersion tests with four-point-bending in the heated 80 °C magnesium chloride solution for SCC showed no difference between AM and reference samples even after a 674 h immersion.

Finite Thickness Influence on Spherical and Conical Indentation on Viscoelastic Thin Polymer Film

2005 ◽  
Vol 127 (1) ◽  
pp. 33-37 ◽  
Author(s):  
V. Gonda ◽  
J. den Toonder ◽  
J. Beijer ◽  
G. Q. Zhang ◽  
L. J. Ernst
Keyword(s):  
Polymer Film ◽  
Material Properties ◽  
Finite Thickness ◽  
Thin Polymer Film ◽  
Spherical Indentation ◽  
Infinite Plane ◽  
Precise Knowledge ◽  
Thin Polymer ◽  
Measurement Results ◽  
Conical Indentation

The thermo-mechanical integration of polymer films requires a precise knowledge of material properties. Nanoindentation is a widely used testing method for the determination of material properties of thin films such as Young’s modulus and the hardness. An important assumption in the analysis of the indentation is that the indented medium is a semi-infinite plane or half space, i.e., it has an “infinite thickness.” In nanoindentation the analyzed material is often a thin film that is deposited on a substrate. If the modulus ratio is small, (soft film on hard substrate) and the penetration depth is small too, then the Hertzian assumption does not hold. We investigate this situation with spherical and conical indentation. Measurement results are shown using spherical indentation on a visco-elastic thin polymer film and a full visco-elastic characterization is presented.

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