Optimization of Bulkhead Processing Sequence for Multi-Frame Monolithic Components by FEM

2007 ◽  
Vol 24-25 ◽  
pp. 355-360 ◽  
Author(s):  
Zhi Tao Tang ◽  
Zhan Qiang Liu ◽  
Xing Ai
Keyword(s):  
Residual Stress ◽  
Material Properties ◽  
Element Model ◽  
Clamping Force ◽  
Processing Sequence ◽  
Initial Residual Stress ◽  
Machining Deformation ◽  
Proposed Model ◽  
Key Techniques ◽  
Monolithic Components

When machining aerospace monolithic components, most of materials could be removed, resulting in severe deformation of the parts due to the release and redistribution of the blank’s original residual stress, together with the action of cutting loads and clamping force. A finite element model (FEM) is built for predicting the deformation caused by those factors mentioned above. In this model, some key techniques such as material properties, initial residual stress model, and application of dynamic cutting loads and transformation of boundary condition are discussed in details. The proposed model predicts the machining deformation for multi-frame monolithic components. Particular attention is paid to the influence of the bulkhead processing sequence on part deformation. At last the paper puts forwards optimal bulkhead processing sequence based on minimizing the machining deformation.

Effect of Process Routing on Machining Deformation for Multi-Frame Double Sided Monolithic Components

2010 ◽  
Vol 97-101 ◽  
pp. 2894-2897 ◽  
Author(s):  
Zhi Tao Tang ◽  
Zhan Qiang Liu ◽  
Li Qiang Xu
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Coordinate Measuring Machine ◽  
Element Model ◽  
Fe Model ◽  
Clamping Force ◽  
Optimal Process ◽  
Machining Deformation ◽  
Measuring Machine ◽  
Monolithic Components

When machining aerospace monolithic components, a severe deformation can be observed due to the release and redistribution of the original residual stresses, together with the action of cutting loads and clamping force. In this paper, a finite element model predicting machining deformation was developed considering the above mentioned multi-factors coupling effects. Based on the model, the effect of process routing on machining deformation for multi-frame double sided monolithic components was studied. To validate the FE model, true frame components were machined and deformations were measured on a Coordinate Measuring Machine. The result revealed that the prediction model is credible. At last the paper puts forwards optimal process routing based on minimizing the machining deformation.

Influence of Initial Residual Stress on Material Properties of Bearing Steel During Rolling Contact Fatigue

2014 ◽  
Vol 57 (3) ◽  
pp. 533-545 ◽  
Author(s):  
Bryan Allison ◽  
Ghatu Subhash ◽  
Nagaraj Arakere ◽  
David A. Haluck ◽  
Herb Chin
Keyword(s):  
Residual Stress ◽  
Material Properties ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Bearing Steel ◽  
Rolling Contact ◽  
Initial Residual Stress

Deformation of the Pneumatic Tire

1978 ◽  
Vol 6 (4) ◽  
pp. 233-247 ◽  
Author(s):  
H. P. Patel ◽  
C. F. Zorowski
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Material Properties ◽  
Thin Shell ◽  
Element Model ◽  
Shell Of Revolution ◽  
Actual Situation ◽  
Pneumatic Tire ◽  
Proposed Model ◽  
Experimental Values

Abstract A finite element model is presented for analysis of axisymmetric static loadings of a bias ply pneumatic tire. The model can predict deformed shapes and the resulting cord forces in the tire. The tire is considered as a thin shell of revolution with membrane and bending stiffness. Its material properties are assumed to be linearly orthotropic. Large axisymmetric deformations studied with the proposed model gave very close approximations to the actual situation. The predicted cord forces matched the experimental values very closely.

Stress Development in the Process for a Hybrid Fiber Wrapping Cylinder

2011 ◽  
Vol 486 ◽  
pp. 151-154
Author(s):  
Ming Fa Ren ◽  
Qi Zhong Huang ◽  
Hao Ran Chen
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Heat Conduction ◽  
Material Properties ◽  
Element Model ◽  
Curing Process ◽  
Hybrid Fiber ◽  
Cure Cycle ◽  
Laminate Theory ◽  
Cure Temperature

In a curing process, there is an intensive residual stress in a cylinder with a reinforced part wrapped by hybrid composite due to the kinds of fibers and mismatch material properties. The development of residual stress in the cylinder is investigated by a finite element model combing with the classical laminate theory and heat conduction. The level of residual stress at the ends of reinforced part is higher than else location, a cure cycle with a lower cure temperature would reduce the residual stress. An improved cure cycle is proposed by comparing the simulational results of the cylinder cured with different cure cycle.

scholarly journals Residual Stress Analysis of a 2219 Aluminum Alloy Ring Using the Indentation Strain-Gauge Method

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 979
Author(s):  
Yunlong Ma ◽  
Nianpu Xue ◽  
Qiong Wu ◽  
Hanjun Gao ◽  
Jian Wu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Strain Gauge ◽  
Expansion Method ◽  
Element Model ◽  
Maximum Principal Stress ◽  
Initial Residual Stress ◽  
2219 Aluminum Alloy ◽  
Rolling Ring ◽  
Indentation Strain

Aerospace thin-walled rings are vulnerable to machining distortion during the manufacturing process. Various research results show that the main factor causing machining deformation is initial residual stress inside the blank. In this study, the residual stress of a 2219 aluminum alloy ultra-large rolling ring was measured by using the indentation strain-gauge method. Results showed the maximum residual maximum principal stress was +265 MPa and stress distribution was uneven. To homogenize the initial residual stress of the ring, an expansion method is proposed based on the principle of pre-stretching plate, and the feasibility of the expansion method was analyzed by establishing a simplified theoretical model of ring. A FE (Finite Element) model was established to investigate residual-stress evolution during the rolling ring and the expanding ring process. The expansion simulation results show that the reduction rates of residual stress were greater than 40% and the maximum residual stress was only 65 MPa.

Numerical Simulation Investigation on Machining Deformation of Aviation Thin-Walled Parts Caused by Residual Stress

2021 ◽  
Vol 1032 ◽  
pp. 186-191
Author(s):  
Jie Deng ◽  
Shi Jie Zhou ◽  
Han Jun Gao ◽  
Ming Hui Lin ◽  
Xin Li
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Residual Stresses ◽  
Simulation Models ◽  
Cutting Parameters ◽  
Stress Distributions ◽  
Machining Deformation ◽  
Proposed Model ◽  
Thin Walled ◽  
Structural Parts

Holistic thin-walled parts are common structural parts of modern aircraft to reduce the weight and increase the stiffness. Over 90% of the materials are removed from the blank, as a result, large machining deformations occur to the parts, which causes the manufacturing discrepancies and even the scrap parts. In this paper, numerical simulation models are established to predict the machining deformation of two typical aviation thin-walled parts. The blank initial and machining induced residual stresses, as well as the cutting parameters, are considered in the model. The deformations and stresses after machining are calculated using the proposed model, and the deformation and stress distributions are analyzed.

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