Finite Element Analysis on Residual Stress of Laser Brazing Diamond Wheel

2013 ◽  
Vol 712-715 ◽  
pp. 739-742 ◽  
Author(s):  
Zhi Bo Yang ◽  
Pei Fei Luo
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Element Model ◽  
Processing Parameters ◽  
Diamond Wheel ◽  
Laser Brazing ◽  
Element Analysis ◽  
The Matrix ◽  
Simulation And Experiment ◽  
Field Element

The purpose of this paper is to simulate the residual field of laser brazing by FEM of ANSYS. The 2-D coupled field element is elected to create finite element model. The brazing experiments have been done by means of 45steel which is the matrix and Ni-Cr solder and the residual stress of the diamond wheel has been measured by Raman method. The results of measure show that the maximum stress value is less strength of diamond. The residual stress distribution is basically identical between the results of simulation and experiment. According to this paper, it is possible to decrease the costs of study by selecting reasonable processing parameters on laser brazing.

Finite Element Analysis for Comprehensive Residual Stress of 7075 Aluminum Alloy Thick Plate

2010 ◽  
Vol 154-155 ◽  
pp. 1255-1261
Author(s):  
Hai Yan Li ◽  
Yi Du Zhang ◽  
Hong Wei Zhang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Thick Plate ◽  
Coupling Effect ◽  
Element Model ◽  
Forming Process ◽  
Element Analysis ◽  
Field Coupling ◽  
Simulation And Experiment

Based on “physical field coupling” finite element method, the generation of residual stress and interactive coupling effect were analyzed during the forming process of aluminum alloy thick-plate. Therefore, comprehensive residual stress generated from rolling, quenching and stretching was obtained. The finite element model was proved effective by comparing the results of simulation and experiment. Results show that percent reduction has significant influence to the distribution and magnitude of rolling stress; There is a coupling effect between rolling stress and quenching stress, which represents a basic state; Furthermore, after stretching the distribution of coupling stress remains, but the value reduces greatly; The residual stress has got the minimum, when stretching is near 3%.

Stress and Fatigue Life Modeling of Cannon Breech Closures Including Effects of Material Strength and Residual Stress

2000 ◽  
Vol 123 (1) ◽  
pp. 150-154
Author(s):  
John H. Underwood ◽  
Michael J. Glennon
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Fatigue Life ◽  
Yield Strength ◽  
Residual Stresses ◽  
Solid Mechanics ◽  
Element Model ◽  
Pressure Vessels ◽  
Material Strength ◽  
Element Analysis

Laboratory fatigue life results are summarized from several test series of high-strength steel cannon breech closure assemblies pressurized by rapid application of hydraulic oil. The tests were performed to determine safe fatigue lives of high-pressure components at the breech end of the cannon and breech assembly. Careful reanalysis of the fatigue life tests provides data for stress and fatigue life models for breech components, over the following ranges of key parameters: 380–745 MPa cyclic internal pressure; 100–160 mm bore diameter cannon pressure vessels; 1040–1170 MPa yield strength A723 steel; no residual stress, shot peen residual stress, overload residual stress. Modeling of applied and residual stresses at the location of the fatigue failure site is performed by elastic-plastic finite element analysis using ABAQUS and by solid mechanics analysis. Shot peen and overload residual stresses are modeled by superposing typical or calculated residual stress distributions on the applied stresses. Overload residual stresses are obtained directly from the finite element model of the breech, with the breech overload applied to the model in the same way as with actual components. Modeling of the fatigue life of the components is based on the fatigue intensity factor concept of Underwood and Parker, a fracture mechanics description of life that accounts for residual stresses, material yield strength and initial defect size. The fatigue life model describes six test conditions in a stress versus life plot with an R2 correlation of 0.94, and shows significantly lower correlation when known variations in yield strength, stress concentration factor, or residual stress are not included in the model input, thus demonstrating the model sensitivity to these variables.

Research on the Effects of Welding Sequence on Welding Residual Stress of High-Speed Train Based on SYSWELD

2011 ◽  
Vol 399-401 ◽  
pp. 1806-1811
Author(s):  
Yong Hong Chen ◽  
Peng Chen ◽  
Ai Qin Tian
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
High Speed ◽  
Element Model ◽  
Welding Residual Stress ◽  
High Speed Train ◽  
Distribution Law ◽  
Element Analysis ◽  
Welding Sequence ◽  
Maximum Residual Stress

The finite element model of the roof of aluminum high-speed train was established, double ellipsoid heat source was employed, and heat elastic-plastic theory was used to simulate welding residual stress of the component under different welding sequence based on the finite element analysis software SYSWELD. The distribution law of welding residual stress was obtained. And the effects of the welding sequence on the value and distribution of residual stress was analyzed. The numerical results showed that the simulation data agree well with experimental test data. The maximum residual stress appears in the weld seam and nearby. The residual stress value decreases far away from the welding center. Welding sequence has a significant impact on the final welding residual stress when welding the roof of aluminum body. The side whose residual stress needs to be controlled should be welded first.

Finite Element Modeling of Hybrid Friction Diffusion Welding of Tube-Tubesheet Joints

2019 ◽  
Author(s):  
Fadi Al-Badour
Keyword(s):  
Finite Element ◽  
Carbon Steel ◽  
Flow Behavior ◽  
Welding Process ◽  
Element Model ◽  
Processing Parameters ◽  
Steel Tube ◽  
Diffusion Welding ◽  
Steel Shell ◽  
Element Analysis

Abstract Hybrid Friction Diffusion Bonding (HFDB) is a solid-state welding process that proved its capability of producing sound tube-tubesheet joints, but with limitations on tube thickness (up to 1mm) and tube-tubesheet materials. In the petrochemical industry, there is a great demand for the use of carbon steel shell and tube heat exchangers. To investigate the feasibility of HFDB techniques in joining thicker tube (i.e 2.1 mm) on tubesheet joint, a three-dimensional thermo-mechanical finite element model (FEM) was developed and solved using ABAQUS (commercial finite element analysis (FEA) software). The model was used to predict the temperature distribution and developed stresses during and after welding. The model considered temperature dependent material properties while Johnson-cook model was used to govern material plastic flow behavior. In this paper,19 mm (¾ in) ASTM 179 cold-drawn carbon steel tube into an ASTM A516 Grade 70 tubesheet joints was simulated. Results are validated based on temperature measurements, which was found in good agreement with experimental results. The developed model can be used to optimize processing parameters (i.e. tool rotational speed, dwell time “holding time”, and forging force.. etc) and study their effect on material flow and developed stresses.

scholarly journals Finite element and biomechanical analysis of risk factors for implant failure during tension band plating

2020 ◽  
Vol 48 (11) ◽  
pp. 030006052097207
Author(s):  
Jing Ding ◽  
Fei Wang ◽  
Fangchun Jin ◽  
Zhen-kai Wu ◽  
Pin-quan Shen
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Finite Element Model ◽  
Three Dimensional ◽  
Biomechanical Model ◽  
Element Model ◽  
Tension Band ◽  
Biomechanical Analysis ◽  
Implant Failure ◽  
Element Analysis

Objective Tension band plating has recently gained widespread acceptance as a method of correcting angular limb deformities in skeletally immature patients. We examined the role of biomechanics in procedural failure and devised a new method of reducing the rate of implant failure. Methods In the biomechanical model, afterload (static or cyclic) was applied to each specimen. The residual stress of the screw combined with different screw sizes and configurations were measured and compared by X-ray diffraction. With regard to static load and similar conditions, the stress distribution was analyzed according to a three-dimensional finite element model. Results The residual stress was close to zero in the static tension group, whereas it was very high in the cyclic load group. The residual stress of screws was significantly lower in the convergent group and parallel group than in the divergent group. The finite element model showed similar results. Conclusions In both the finite element analysis and biomechanical tests, the maximum stress of the screw was concentrated at the position where the screws enter the cortex. Cyclic loading is the primary cause of implant failure.

Finite Element Analysis of Effects of Preheating and Postweld Heat Treatment on Residual Stress in Pipe Welding

2011 ◽  
Vol 314-316 ◽  
pp. 428-431 ◽  
Author(s):  
Hui Du ◽  
Dong Po Wang ◽  
Chun Xiu Liu ◽  
Hai Zhang
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Finite Element ◽  
Stress Distribution ◽  
Welding Process ◽  
Postweld Heat Treatment ◽  
Element Model ◽  
Element Analysis ◽  
Pipe Welding ◽  
Postweld Heat

To simulate preheating and postweld heat treatment of Q345 steel pipe welding, the finite element model was established. The welding process was simulated by method of the ANSYS element birth and death technique. In this paper, to obtain the distribution of the temperature field and stress field in different situations, preheating processes with two different values of temperature and postweld heat treatment process were simulated respectively. The results show that preheating can homogenize residual stress distribution of the weldment and decrease the residual stress. The heat treatment reduces the residual stress in inner and outer walls by 24% and 70% respectively and the stress distribution is more even and stress concentration is reduced.

Numerical Analysis of the Effect of Machining on the Depth of Yield, Maximum Firing Pressure and Residual Stress Profile in an Autofrettaged Gun Tube

2003 ◽  
Vol 125 (3) ◽  
pp. 342-346 ◽  
Author(s):  
Amer Hameed ◽  
R. D. Brown ◽  
J. G. Hetherington
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Optimization Technique ◽  
Circumferential Stress ◽  
Element Model ◽  
Stress Profile ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Residual Stress Profile ◽  
Experimental Findings

A multi-linear kinematic, two dimensional finite element model incorporating Bauschinger effect, developed using ANSYS commercial software is used to determine the effect of machining both at the bore and at the outside diameter, on the depth of yield, maximum firing pressure and final residual stress field present in an autofrettaged gun tube. The model, which is in good agreement with experimental findings, clearly shows that the reduction in maximum compressive circumferential stress is more sensitive to internal machining than to external machining; the depth of yield remains stable and there is no movement of the elastic-plastic interface, relative to its location before material removal. If the internal machining removes material in which reverse yield has occurred, the maximum firing pressure is not affected. The finite element analysis supported by experimental evidence thus leads to an optimization technique for gun tube design.

Three Dimensional Finite Element Analysis of a Split-Sleeve Cold Expansion Process

2009 ◽  
Vol 131 (3) ◽  
Author(s):  
S. Ismonov ◽  
S. R. Daniewicz ◽  
J. C. Newman ◽  
M. R. Hill ◽  
M. R. Urban
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Residual Stress Field ◽  
Expansion Process ◽  
Element Analysis ◽  
Cold Expansion ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

A cold expansion process is used to prolong the fatigue life of a structure under cyclic loadings. The process produces a beneficial compressive residual stress zone in the hole vicinity, which retards the initiation and propagation of the crack at the hole edge. In this study, a three-dimensional finite element model of the split-sleeve cold expansion process was developed to predict the resulting residual stress field. A thin rectangular aluminum sheet with a centrally located hole was considered. A rigid mandrel and an elastic steel split sleeve were explicitly modeled with the appropriate contact elements at the interfaces between the mandrel, the sleeve, and the hole. Geometrical and material nonlinearities were included. The simulation results were compared with experimental measurements of the residual stress. The influence of friction and the prescribed boundary conditions for the sheet were studied. Differences between the split-sleeve- and the non-split-sleeve model solutions are discussed.

3D Finite Element Analysis of Prestressed Cutting

2012 ◽  
Vol 591-593 ◽  
pp. 766-770 ◽  
Author(s):  
Rui Tao Peng ◽  
Fang Lu ◽  
Xin Zi Tang ◽  
Yuan Qiang Tan
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Bearing Steel ◽  
Arbitrary Lagrangian Eulerian ◽  
Machined Surface ◽  
Element Analysis ◽  
Simulation Techniques ◽  
Ale Formulation

In order to reveal the adjustment principle of prestressed cutting on the residual stress of hardened bearing steel GCr15, a three-dimensional thermal elastic-viscoplastic finite element model was developed using an Arbitrary Lagrangian Eulerian (ALE) formulation. Several key simulation techniques including the material constitutive model, constitutive damage law and contact with friction were discussed, simulation of chip formation during prestressed cutting was successfully conducted. At the prestresses of 0 MPa, 341 MPa and 568 MPa, distributions of residual stress on machined surface were simulated and experimentally verified. The results indicated that residual compressive stress on machined surface were achieved and actively adjusted by utilizing the prestressed cutting method; meanwhile, within the elastic limit of bearing steel material, the higher applied prestress leads to the more prominent compressive residual stress in the surface layer and subsequently the higher fatigue resistance of the part.

LENGTH AND WIDTH EFFECTS OF METAL FILMS ON STRESS-INDUCED BENDING OF SURFACE MICROMACHINED CANTILEVER CURVED GRATING

2012 ◽  
Vol 19 (01) ◽  
pp. 1250001 ◽  
Author(s):  
JU-NAN KUO
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Plane Deformation ◽  
Beam Theory ◽  
Element Model ◽  
Metal Films ◽  
Width Ratio ◽  
Element Analysis ◽  
Close Relationship ◽  
Out Of Plane

In this study, the length and width effects of metal films on the stress-induced bending of a surface micromachined cantilever curved grating are systematically investigated. A characterization of cantilever curved gratings with various lengths and widths was conducted to observe out-of-plane deformation. A finite element model was established to analyze the deformation. Finite element analysis and experimental results indicate that the commonly used beam theory formula for predicting the deformation of surface micromachined cantilever curved gratings is not valid for these devices. Experiments show that the shape of a cantilever curved grating and residual stress have a close relationship. As the length increases, the residual stress of the metal increases, resulting in a larger out-of-plane deformation of the cantilever curved grating. The tip deflection gradually decreases as the length-to-width ratio of the cantilever curved grating increases. A more reliable shape design of metal films on the stress-induced bending of surface micromachined cantilever curved gratings can thus be achieved.

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