scholarly journals Evolution Analysis of Process-induced Residual Stress During the Manufacture of Diesel Body

2021 ◽  
Author(s):  
Donghao Zhao ◽  
Zhuhua Ai ◽  
Yunlong Liu ◽  
Guochao Li ◽  
Honggen Zhou ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Machining Process ◽  
Analysis Method ◽  
Analysis Model ◽  
Treatment Processes ◽  
Evolution Analysis ◽  
Independent Analysis ◽  
Final Stress ◽  
Cutting Processes

Abstract Residual stress is most likely to cause deformation in a diesel body (DB). The traditional independent analysis method is no longer suitable for obtaining the residual stress of multi-process DBs, because the stress is constantly produced and changed during the casting, heat treatment, and cutting processes. Therefore, an evolution analysis method(EAM) is proposed. First, an evolution analysis model of a DB was established. Subsequently, the residual stress of the DB in the casting and heat treatment processes was analysed using ProCAST and ABAQUS. Finally, the material removal of the DB during the machining process was simulated by using ABAQUS. The residual stresses for every process were calculated by coupling inherited and process-induced stresses. Thus, the final stress distribution of the DB was deduced by considering the entire machining process. The evolution analysis of the residual stress is significant for controlling the deformation of the DB.

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

2021 ◽  
Author(s):  
James Jan ◽  
Steve Swisher ◽  
Mohammed Yusuf Ali ◽  
Shanmugasundaram Chandrakesan
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Data Exchange ◽  
Casting Process ◽  
Cost Effective ◽  
Software Tools ◽  
Product Launch ◽  
Cylinder Block ◽  
Virtual Engineering ◽  
Final Stress

Abstract Engine cylinder block cracking is a costly engine component failure that is often discovered late, either in the product verification phase by dynamometer testing or after product launch during vehicle operations. It is well established that the crack issues are related to the residual stress induced in the casting and heat treatment processes. To identify the quality risk in a short turn-around time and a cost-effective fashion, using computer simulations to evaluate the state of stress during casting and heat treat processes is the trend in automotive industry. In recent years, CAE methodologies have advanced significantly in both CFD and FEA to model the casting process, the quenching process, the residual stress, and the high cycle fatigue (HCF). However, calculating the final stress in the cylinder block requires several CAE software tools to work together as an integrated, streamlined engineering method and these CAE tools could be very different in meshing topologies, numerical methods, data structure, and post-processing capabilities. The intent of this research is to develop an integrated virtual engineering methodology combining casting simulation, computational fluid dynamics and finite element method to simulate the manufacturing process from the beginning of casting, through water quenching heat treatment, to engine dynamometer testing. The methodology involves three CAE tools, MAGMASOFT®, AVL FIRETM/FIRETM-M and ABAQUS, and considerable amounts of research and development work are concentrated on the validation of each individual numerical method and tools for data exchange between the software tools.

scholarly journals Effect of heat treatment residual stress on stress behavior of constant stress beam

2017 ◽  
Vol 5 (1) ◽  
pp. 137-143 ◽  
Author(s):  
Si Young Kwak ◽  
Ho Young Hwang
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
External Load ◽  
Treatment Process ◽  
Constant Stress ◽  
Design Stage ◽  
Treatment Processes ◽  
Stress Behavior ◽  
Treatment Step ◽  
Heat Treatment Step

Abstract Although most casting and heat treatment processes generate significantly high residual stress in the products, this factor is generally not taken into account in the design stage of the product. In this study, experimental study and numerical analysis were conducted on a constant stress beam to examine effects of the residual stress generated during the heat treatment process on yielding behavior of the product in use. A constant stress beam of SUS 304 was designed in order to test the stress behavior related to residual stress. The residual stresses generated during quenching heat treatment of the beam were measured in advance by ESPI (Electronic Speckle-Pattern Interferometry) equipment, and then the external stresses generated while applying a simple external load on the beam were measured. Also, the residual stress distribution generated during the heat treatment process was computed using a numerical analysis program designed for analyzing heat treatment processes. Then, the stress distribution by a simple external load to the beam was combined with the calculated residual stress results of the previous heat treatment step. Finally, the results were compared with experimental ones. Simulation results were in good agreement with the experimental results. Consistency between experimental results and computational results prove that residual stress has significant effects on the stress behavior of mechanical parts. Therefore, the residual stress generated in the previous heat treatment step of casting must be taken into account in the stage of mechanical product design. Highlights The bigger compressive residual stress occurs, the closer surface. When the residual stress is close to plastic deformation, the stress by external load did not significantly change. The residual stress generated during the manufacturing process should be considered in the design stage.

scholarly journals Residual Stress Measurement in Heat Treated Cylindrical Components

2021 ◽  
Author(s):  
M. Belassel ◽  
J. Pineault ◽  
M. Bolla ◽  
M. Brauss
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Microstructural Characterization ◽  
Plain Carbon Steel ◽  
X Ray Diffraction ◽  
Treatment Processes ◽  
Heat Treated ◽  
Xrd Techniques

Abstract Heat treatment processes can generate steep residual stress (RS) gradients and plastic deformation in metal components due to differential cooling and other effect such as phase transformation. The magnitude of residual stresses generated, and how quickly they vary spatially, will depend upon the material itself and the temperature gradients introduced during the heat treatment process. X-ray diffraction (XRD) techniques can be used to characterize residual stresses, as well as microstructural changes, including dislocation density and particle size in heat treated components. Plain carbon steel cylinders were heat treated, quenched and characterized using these methods. Residual stress measurements were performed via XRD using the Sin2Ψ technique and microstructural characterization was evaluated using the associated peak widths. Measurements were carried out both at the surface and through depth using electropolishing. The results indicate triaxial stress gradients exist in all samples investigated, with concomitant varying microstructural characteristics.

Strength Analysis of High Strength Steel Hydraulic Support

2012 ◽  
Vol 184-185 ◽  
pp. 676-679
Author(s):  
Shuan Wei Cui ◽  
Yi Liang Zhang
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
High Strength ◽  
Working Environment ◽  
Welding Residual Stress ◽  
Strength Analysis ◽  
Hydraulic Support ◽  
Treatment Processes ◽  
Before And After ◽  
Main Components

Based on the importance and complex working environment of hydraulic support, welding residual stress (WRS) measurement to main components were carried out respectively by X-ray diffraction and the measured data were further analyzed theoretically. Tests were made on the gob shield and base for two times, each was measured before and after heat treatment respectively. The results indicate that WRS in the base are higher than that in the gob shield before heat treatment. After heat treatment, residual stress (RS) level of gob shield and base decreased significantly, WRS in every region keep at a lower level and regional RS differences become smaller. Therefore, heat treatment processes is an effective method to reduce RS of hydraulic support after welding. Through the test results we measured, got the real residual stress level of gob shield and base, which can provide the basis of experiment to search for an appropriate welding and heat treatment process.

Experimental and Numerical Investigation of Sub-Clad and Surface Cracks in Cladded Components

2008 ◽  
Author(s):  
Jo¨rg Hohe ◽  
Marcus Brand ◽  
Dieter Siegele
Keyword(s):  
Numerical Simulation ◽  
Heat Treatment ◽  
Residual Stress ◽  
Crack Extension ◽  
Fracture Behavior ◽  
Large Scale ◽  
Ferritic Steels ◽  
Surface Cracks ◽  
Residual Stress Field ◽  
Treatment Processes

The present study is concerned with the fracture behavior of sub-clad and surface cracks in components consisting of ferritic steels with an austenitic welded cladding. For this purpose, two tests on large scale specimens have been performed. The residual stress field has been determined by means of a numerical simulation of the welding and heat treatment processes. Based on the results, a numerical simulation of the component tests was performed in order to enable a fracture mechanics assessment of the conditions leading to crack initiation and arrest in the ferritic and austenitic regions. It was observed that in the present tests failure was initiated in the ferritic material whereas the austenitic cladding remained stable even in the case of a limited crack extension in the ferritic base metal.

INFLUENCE THE QUENCHING AND TEMPERING ON THE MICROSTRUCTURE, MECHANICAL PROPERTIES AND SURFACE ROUGHNESS, OF MEDIUM CARBON STEEL

2018 ◽  
Vol 18 (1) ◽  
pp. 125-135
Author(s):  
Sattar H A Alfatlawi
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Surface Roughness ◽  
Carbon Steel ◽  
Cold Water ◽  
Medium Carbon Steel ◽  
Medium Carbon ◽  
Heating And Cooling ◽  
Treatment Processes ◽  
Quenching And Tempering

One of ways to improve properties of materials without changing the product shape toobtain the desired engineering applications is heating and cooling under effect of controlledsequence of heat treatment. The main aim of this study was to investigate the effect ofheating and cooling on the surface roughness, microstructure and some selected propertiessuch as the hardness and impact strength of Medium Carbon Steel which treated at differenttypes of heat treatment processes. Heat treatment achieved in this work was respectively,heating, quenching and tempering. The specimens were heated to 850°C and left for 45minutes inside the furnace as a holding time at that temperature, then quenching process wasperformed in four types of quenching media (still air, cold water (2°C), oil and polymersolution), respectively. Thereafter, the samples were tempered at 200°C, 400°C, and 600°Cwith one hour as a soaking time for each temperature, then were all cooled by still air. Whenthe heat treatment process was completed, the surface roughness, hardness, impact strengthand microstructure tests were performed. The results showed a change and clearimprovement of surface roughness, mechanical properties and microstructure afterquenching was achieved, as well as the change that took place due to the increasingtoughness and ductility by reducing of brittleness of samples.

Management of Guidance and Counseling on Learning Discipline

2020 ◽  
Vol 10 (2) ◽  
pp. 60-74
Author(s):  
Muhammad Syauqi Mubarok
Keyword(s):  
Statistical Analysis ◽  
Descriptive Analysis ◽  
Field Studies ◽  
Guidance And Counseling ◽  
Analysis Method ◽  
Vocational High School ◽  
Analysis Model ◽  
Survey Techniques ◽  
Analysis Technique ◽  
Path Analysis Model

This article aims to examine and describe the influence of guidance and counseling management on learning discipline. The method used in this research is descriptive analysis method using survey techniques. Data collection techniques that used are documentation studies and field studies. Moreover, the data analysis technique that has been used to answer the research hypothesis is statistical analysis with a path analysis model. The location of the study was at the Ciledug Vocational High School Al-Musaddadiyah Garut, with 85 respondents taking part in the survey. The results of the discussion show that guidance and counseling management has a positive and significant effect on the discipline of learning

Effect of Two-step Heat Treatment Processes on the Formation of Protein Particles and Oil Droplets in Soymilk

2020 ◽  
Vol 26 (3) ◽  
pp. 445-450
Author(s):  
Makoto Shimoyamada ◽  
Hironori Shikano ◽  
Shingo Mogami ◽  
Makoto Kanauchi ◽  
Hayato Masuda ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Oil Droplets ◽  
Treatment Processes ◽  
Protein Particles ◽  
Step Heat Treatment
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