scholarly journals A Data-Driven Method for Predicting Deformation of Machined Parts Using Sparse Monitored Deformation Data

2021 ◽  
Author(s):  
Zhiwei Zhao ◽  
Yingguang Li ◽  
Yee Mey Goh ◽  
Changqing Liu ◽  
Peter Kinnell
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Machining Process ◽  
Data Driven ◽  
Residual Stress Field ◽  
Deformation Prediction ◽  
Machined Parts ◽  
Internal Stress Field ◽  
Research Challenge ◽  
Monolithic Components

In the aircraft industry, where high precision geometric control is vital, unexpected component deformation, due to the release of internal residual stress, can limit geometric accuracy and presents process control challenges. Prediction of component deformation is necessary so that corrective control strategy can be defined. However, existing prediction methods, that are mainly based on the prediction or measurement of residual stress, are limited and accurate deformation prediction is still a research challenge. To address this issue, this paper presents a data-driven method for deformation prediction based on the use of in-process monitored deformation data. Deformation, which is caused by an unbalanced internal residual stress field, can be accurately monitored during the machining process via an instrumented fixture device. The state of the internal stress field within the part is first estimated by the using the part deformation data collected during machining process, and then, the deformation caused by a subsequent machining process is predicted. Deep learning is used to establish the estimating module and predicting module. The estimating module is used to infer the unobservable residual stress field as vectors by using sparse deformation data. The inferred vector is then used to predict the deformation in the predicting module. The proposed method provides an effective way to predict deformation during the machining of monolithic components, which is demonstrated experimentally.

A Numerical Study on the Redistribution of Residual Stress After Machining

2017 ◽  
Author(s):  
Kunyang Lin ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Numerical Study ◽  
Cutting Speed ◽  
Machining Process ◽  
Stress Profile ◽  
Residual Stress Field ◽  
Machining Processes ◽  
Residual Stress Profile

Machining induced residual stresses have an important effect on the surface integrity. Effects of various factors on the distribution of residual stress profiles induced by different machining processes have been investigated by many researchers. However, the initial residual, as one of the important factor that affect the residual stress profile, is always been ignored. In this paper, the residual stress field induced by the quenching process is simulated by the FEM software as the initial condition. Then the initial residual stress field is used to study the residual stress redistribution after the machining process. The influence of initial stress on the stress formation is carried out illustrating with the mechanical and thermal loads during machining processes. The effects of cutting speed on the distribution of residual stress profile are also discussed. These results are helpful to understand how initial residual stresses are redistributed during machining better. Furthermore, the results in the numerical study can be used to explain the machining distortion problem caused by residual stress in the further work.

The Change in Overstrain Level Resulting From Machining of an Autofrettaged Thick-Walled Cylinder

1999 ◽  
Vol 122 (1) ◽  
pp. 9-14 ◽  
Author(s):  
M. Perl
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Thermal Load ◽  
Machining Process ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Gun Barrel ◽  
Algebraic Expressions ◽  
Walled Cylinder

An analytical model for predicting the level of autofrettage following either inner, outer, or combined machining of a gun barrel is developed based on Hill’s (Hill, R., 1950, The Mathematical Theory of Plasticity, Clarendon Press, Oxford, U.K.) solution for the autofrettage residual stress field. The analysis results in very simple algebraic expressions for the post-machining level of autofrettage in terms of the original level induced in the blank tube. In parallel, a finite element analysis of the machining process is performed in which the residual stress field is simulated by an equivalent thermal load. The numerical results are found to be in excellent agreement with the analytical ones. Thus, as an equivalent thermal load can always be determined, either analytically or numerically, for any other approximations to the residual stress field due to autofrettage (Perl, M., 1988, ASME J. Pressure Vessel Technol., 110, pp. 100–102), the foregoing methodology can be readily applied, enabling the determination of post-machining autofrettage level in these cases. [S0094-9930(00)00501-1]

scholarly journals Residual stresses in thermite welded rails: significance of additional forging

2020 ◽  
Vol 64 (7) ◽  
pp. 1195-1212
Author(s):  
B. Lennart Josefson ◽  
R. Bisschop ◽  
M. Messaadi ◽  
J. Hantusch
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Weld Metal ◽  
Welding Process ◽  
Surface Zone ◽  
Fe Model ◽  
Uneven Surface ◽  
Residual Stress Field ◽  
High Dynamic

Abstract The aluminothermic welding (ATW) process is the most commonly used welding process for welding rails (track) in the field. The large amount of weld metal added in the ATW process may result in a wide uneven surface zone on the rail head, which may, in rare cases, lead to irregularities in wear and plastic deformation due to high dynamic wheel-rail forces as wheels pass. The present paper studies the introduction of additional forging to the ATW process, intended to reduce the width of the zone affected by the heat input, while not creating a more detrimental residual stress field. Simulations using a novel thermo-mechanical FE model of the ATW process show that addition of a forging pressure leads to a somewhat smaller width of the zone affected by heat. This is also found in a metallurgical examination, showing that this zone (weld metal and heat-affected zone) is fully pearlitic. Only marginal differences are found in the residual stress field when additional forging is applied. In both cases, large tensile residual stresses are found in the rail web at the weld. Additional forging may increase the risk of hot cracking due to an increase in plastic strains within the welded area.

A mechanism study on characteristic curve of residual stress field in Ti–6Al–4V induced by wet peening treatment

2015 ◽  
Vol 86 ◽  
pp. 761-764 ◽  
Author(s):  
Kang Li ◽  
Xue-song Fu ◽  
Rui-dong Li ◽  
Wen-long Zhou ◽  
Zhi-qiang Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Characteristic Curve ◽  
Mechanism Study ◽  
Residual Stress Field

Dynamic evolution of welding residual stress field under noncontact electromagnetic force

2010 ◽  
Vol 107 (5) ◽  
pp. 054904
Author(s):  
Da Xu ◽  
Xuesong Liu ◽  
Ping Wang ◽  
Jianguo Yang ◽  
Wei Xu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Electromagnetic Force ◽  
Welding Residual Stress ◽  
Dynamic Evolution ◽  
Residual Stress Field

Analysis of Thermal Stresses and Residual Stress Changes in Railroad Wheels Caused by Severe Drag Braking

1977 ◽  
Vol 99 (1) ◽  
pp. 18-23 ◽  
Author(s):  
M. R. Johnson ◽  
R. E. Welch ◽  
K. S. Yeung
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Yield Point ◽  
Thermal Stresses ◽  
Material Behavior ◽  
Nonlinear Material ◽  
Residual Stress Field ◽  
Thermal Stress Field ◽  
Stress Changes ◽  
Railroad Wheels

A finite-element computer program, which takes into consideration nonlinear material behavior after the yield point has been exceeded, has been used to analyze the thermal stresses in railroad freight car wheels subjected to severe drag brake heating. The analysis has been used with typical wheel material properties and wheel configurations to determine the thermal stress field and the extent of regions in the wheel where the yield point is exceeded. The resulting changes in the residual stress field after the wheel has cooled to ambient temperature have also been calculated. It is shown that severe drag braking can lead to the development of residual circumferential tensile stresses in the rim and radial compressive stresses in the plate near both the hub and rim fillets.

On the residual stress field induced by a scratching round abrasive grain

Wear ◽  
2010 ◽  
Vol 269 (1-2) ◽  
pp. 86-92 ◽  
Author(s):  
G. Kermouche ◽  
J. Rech ◽  
H. Hamdi ◽  
J.M. Bergheau
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stress Field ◽  
Abrasive Grain
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