Numerical Analyses of Turning-Induced and Mapped Ti6Al4V Residual Stresses for a Disc Subjected to Centrifugal Loading

2011 ◽  
Vol 5 (3) ◽  
pp. 326-333 ◽  
Author(s):  
Shukri Afazov ◽  
◽  
Svetan Ratchev ◽  
Adib Becker ◽  
Shulong Liu ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Numerical Analyses ◽  
Hole Drilling ◽  
Depth Of Cut ◽  
Fe Model ◽  
X Ray Diffraction ◽  
Centrifugal Load ◽  
Centrifugal Loading ◽  
Mapping Techniques

The paper investigates the effects of turning-induced and mapped Residual Stresses (RSs) for a Ti6Al4V disc subjected to centrifugal loading. The turninginduced RSs are predicted in orthogonal cutting using the Finite Element Method (FEM). The FE predicted RSs are validated after performing face turning followed by hole drilling and x-ray diffraction measurements. Numerical analyses are carried out at different Cutting Velocities (CVs) to obtain the RS profiles. The results show that the compressive RSs increase by increasing the CV and the depth of cut. A disc subjected to a centrifugal load is modelled using the FEM where the turning-induced RSs are introduced as an initial condition using mapping techniques. The predicted CV-dependent RS profiles are incorporated into the mapping techniques using the shape function approach. It is observed that the stress amplitudes at the points at which failure occurs are lower when the mapped turning-induced RS profiles are considered in the disc FE model. The lower stress amplitudes are related to prolonging the disc life due to fatigue.

scholarly journals Influence of Cutting Speed on Residual Stresses by Machining of AISI 316L

2020 ◽  
Vol 38 (3A) ◽  
pp. 394-401
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
X Ray Diffraction ◽  
Beverage Industry ◽  
Food And Beverage Industry ◽  
Food And Beverage ◽  
Cutting Speeds

RS have an important role in the performance of components and machined structures. The objective of this paper is to study the influence of cutting speed on RS in workpieces that are formed in orthogonal cutting. AISI 316L stainless steel since it has been used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, and food and beverage industry. Four cutting speeds are selected: (44, 56, 71 and 88) m/min. The alloy was machined by turning at constant depth of cut and various feed rate from (0.065 to 0.228) mm/rev. Residual stresses are examined by X-ray diffraction. The best results of RS obtained are (-3735.28, -1784.95, -330.142, -218.747, -890.758, -2999.632, -2990.401) MPa. Increasing the cutting speed from (44-56) m/min. reduces the compressive residual stress by (21.4 %), while from (71-88) m/min the RS is reduced by (19.3 %). Finally, the RS at cutting speeds are changed from compression to tension.

Experimental and Numerical Investigation into Residual Stress During Turning Operation for Stainless Steel AISI 316

2020 ◽  
Vol 38 (12A) ◽  
pp. 1862-1870
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Main Role ◽  
Turning Operation ◽  
Aisi 316

RS (residual stresses) represent the main role in the performance of structures and machined parts. The main objective of this paper is to investigate the effect of feed rate with constant cutting speed and depth of cut on residual stresses in orthogonal cutting, using Tungsten carbide cutting tools when machining AISI 316 in turning operation. AISI 316 stainless steel was selected in experiments since it is used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, food and beverage industry. Four feed rates were selected (0.228, 0.16, 0.08 and 0.065) mm/rev when cutting speed is constant 71 mm/min and depth of cutting 2 mm. The experimental results of residual stresses were (-15.75, 12.84, 64.9, 37.74) MPa and the numerical results of residual stresses were (-15, 12, 59, and 37) MPa. The best value of residual stresses is (-15.75 and -15) MPa when it is in a compressive way. The results showed that the percentage error between numerical by using (ABAQUS/ CAE ver. 2017) and experimental work measured by X-ray diffraction is range (2-15) %.

scholarly journals The Effect of Specimen Size on Residual Stresses in Friction Stir Welded Aluminum Components

2014 ◽  
Vol 996 ◽  
pp. 445-450 ◽  
Author(s):  
Wulf Pfeiffer ◽  
Eduard Reisacher ◽  
Michael Windisch ◽  
Markus Kahnert
Keyword(s):  
Residual Stresses ◽  
Specimen Size ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
X Ray ◽  
Friction Stir ◽  
Metal Parts ◽  
Hole Drilling Method ◽  
Incremental Hole Drilling ◽  
Drilling Method

Friction stir welding (FSW) is a well-known technique which allows joining of metal parts without severe distortion. Because FSW involves less heat input relative to conventional welding, it may be assumed that cutting specimens from larger friction stir welded components results in a negligible redistribution of residual stresses. The aim of the investigations was to verify these assumptions for a welded aluminum plate and a circumferentially-welded aluminum cylinder. Strain gage measurements, X-ray diffraction and the incremental hole drilling method were used.

An Analysis of Residual Stress Improvement for a Dissimilar Metal Nozzle-to-Pipe Weld by Using the Heat Sink Method

2008 ◽  
Author(s):  
J.-S. Park ◽  
J.-M. Kim ◽  
G.-H. Sohn ◽  
Y.-H. Kim
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Heat Sink ◽  
Nuclear Power ◽  
Power Plants ◽  
Base Alloy ◽  
Fatigue Cracking ◽  
Hole Drilling ◽  
Fe Model ◽  
Dissimilar Metal

This study is concerned with the mechanics analysis of residual stress improvement by the heat sink method applied to a dissimilar metal weld (DMW) for the use in nuclear power plants. The DMW joint considered here is composed of ferritic low-alloy steel nozzle, austenitic stainless steel safe-end, and nickel-base alloy A52 weld metal. To prepare the DMW joint with a narrow-gap, the gas tungsten arc welding (GTAW) process is utilized, and the heat sink method is employed to control thermal gradients developed in the critical region of work pieces during welding. Weld residual stresses are computed by the non-linear thermal elasto-plastic analysis using the axisymmetric finite element (FE) model, for which temperature-dependent thermal and mechanical properties of the materials are considered. A full-scale mock-up test is conducted to validate analytical solution for the DMW joint, and residual stresses are measured by using the hole-drilling method. Results of the FE modeling and mock-up test for the DMW joint are compared and effects of the heat sink method are discussed. It is found that a significant amount of residual compressive stresses can be developed on the inner surface of the DMW joint by using the heat sink method, which can effectively reduce the susceptibility of the welded materials to stress corrosion or fatigue cracking.

scholarly journals Effect of Speed, Feed and Depth of Cut on Machining Induced Residual Stresses in Aisi 1045 Steel

2019 ◽  
Vol 8 (2) ◽  
pp. 3397-3400 ◽  
Keyword(s):  
Residual Stresses ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
X Ray Diffraction ◽  
Left Behind ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Predicted Values ◽  
Future Work ◽  
1045 Steel

Residual stress that are induced during machining of components plays a significant part in the endurance and life of the component. The magnitude and nature of the residual stresses have been of interest to many researchers across the globe. The present work involves methodology to find out the influence of factors on the residual stresses. The machining parameters were varied and the residual stresses were determined using non-destructive method, namely X-ray diffraction. Using statistical methods, the influence of the machining parameters was ascertained. This paper aims at investigating the residual stresses in AISI 1045 steel, induced due to milling. AISI 1045 steel was considered as it is a widely used material and its applications are innumerable. It was observed that speed and feed have significant influence on stresses left behind after the machining is completed. Using statistical techniques a mathematical model was developed which is further used to predict the residual stresses. The error percentage of the predicted values was less than 5%. The results obtained were promising and future work involves the optimization of the machining parameters.

Shakedown During Fatigue of Residual Stresses Introduced by Different Mechanical Surface Treatments

2006 ◽  
Author(s):  
Christopher M. Gill ◽  
Philip J. Withers ◽  
Alex Evans ◽  
Neil Fox ◽  
Koichi Akita
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Glass Bead ◽  
Compressive Residual Stress ◽  
Cold Work ◽  
Diffraction Method ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
X Ray ◽  
Cold Worked

A layer of compressive residual stress extending from the surface of a component can help to extend fatigue life, but it must remain stable during applied service loading. Metal shot and glass bead peening are traditionally used; introducing a shallow (100–300μm) layer of compressive residual stress and a highly cold worked surface. Laser peening and deep rolling are capable of introducing much deeper compressive residual stresses combined with lower levels of cold work. In this paper we report on the level of shakedown of residual stress brought about by constant strain amplitude fatigue. Glass and metal shot peened, laser peened and deep rolled Ti-6Al-4V samples have been studied. The residual stress profiles as a function of depth have been measured using neutron diffraction, laboratory x-ray diffraction and a hybrid hole-drilling/laboratory x-ray diffraction method. The magnitude and depth of cold work determined for each of the treatment methods. The extent of subsequent residual stress shakedown under different strain amplitudes and load ratios, in deep rolled, glass bead and metal shot peened samples is also assessed.

Comparative Analysis of Shot-Peening Residual Stresses Using Hole-Drilling and X-Ray Diffraction Methods

2000 ◽  
Vol 347-349 ◽  
pp. 138-143 ◽  
Author(s):  
Joao P. Nobre ◽  
Martin Kornmeier ◽  
A. Morão Dias ◽  
Berthold Scholtes
Keyword(s):  
Comparative Analysis ◽  
Residual Stresses ◽  
Shot Peening ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
X Ray

scholarly journals Assessing Shot-Peening Residual Stresses by Using the Incremental Hole-Drilling Technique and Laser Interferometry (DSPI)

2014 ◽  
Vol 996 ◽  
pp. 269-276
Author(s):  
João P. Nobre ◽  
Miguel Oliveira ◽  
Armando Albertazzi ◽  
Matias Viotti ◽  
António Castanhola Batista ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Shot Peening ◽  
Speckle Pattern ◽  
Strain Relaxation ◽  
Laser Interferometry ◽  
Hole Drilling ◽  
X Ray Diffraction ◽  
Incremental Hole Drilling ◽  
Drilling Technique

The incremental hole-drilling technique was applied to determine residual stress profiles in shot-peened steel layers. The accuracy of using an enhanced Digital Speckle Pattern Interferometry technique for measuring the strain relaxation arising around the drilled holes and, consequently, the in-depth residual stress distribution induced by shot-peening, was evaluated. The experimental results were systematically compared with those determined using standard electric strain-gauges. The X-ray diffraction technique was chosen as reference due to its high accuracy to determine shot-peening residual stresses.

Evaluation of the Integrity of PWR Bimetallic Welds

2000 ◽  
Vol 122 (3) ◽  
pp. 368-373 ◽  
Author(s):  
Josette Devaux ◽  
Ge´rard Mottet ◽  
Jean-Michel Bergheau ◽  
Surender K. Bhandari ◽  
Claude Faidy
Keyword(s):  
Residual Stresses ◽  
Diffraction Method ◽  
Hole Drilling ◽  
Material Structure ◽  
X Ray Diffraction ◽  
X Ray ◽  
Circumferential Crack ◽  
Incremental Hole Drilling ◽  
Drilling Technique ◽  
Made In

This paper presents the state of the art and the progress made in the numerical simulation of the stress state in a complex multi-material structure, using not only sophisticated finite element tools, but also the simplified engineering methods. A comparison of the numerical results concerning residual stresses is made with those measured using X-ray diffraction method and incremental hole-drilling technique. Finally, an example is given on the analysis of a fully circumferential crack in a typical bimetallic weld under pressure, thermal, and residual stresses. [S0094-9930(00)00703-4]

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