Modelling of Residual Stresses Induced by Turning of 316L

2009 ◽  
Vol 83-86 ◽  
pp. 230-236 ◽  
Author(s):  
F. Valiorgue ◽  
J. Rech ◽  
H. Hamdi ◽  
P. Gilles ◽  
J.M. Bergheau
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Parameters ◽  
Stress Generation ◽  
Workpiece Surface ◽  
New Approach ◽  
Residual Stress State ◽  
Cutting Operation ◽  
Experimental Works ◽  
The Impact

Residual stresses are very important for the lifetime of pieces in their mechanisms. These kind of damages are mainly caused by mechanical, thermal, and metallurgical affectations of the machined material. To control these affectations, we need to link the cutting parameters to the residual stress state observed onto the workpiece surface and depth. These connections can be made with analytical works, experimental works or numerical works. In our case, it has been chosen to work with a numerical support in order to observe and understand precisely the phenomenon involved during cutting operation. While this way of study is really popular, we proposed to model the residual stress generation in a original way by keeping aside the chip formation. This new approach presented in a previous paper was simple and only use a 2D model. This first model moves thermo mechanical loadings onto the workpiece surface to recreate the relative motion between the tool and the workpiece. The new 3D model, presented in this paper, is now improved with an original friction law. It underlines the impact of each passage of the tool onto the others. The physical properties are thermo dependant and the flow stress model is based on a Johnson cook behaviour.

Research on Cutting Residual Stresses Based on Thermo-Mechanical Coupling

2009 ◽  
Vol 628-629 ◽  
pp. 651-656
Author(s):  
Ying Qiang Xu ◽  
S.J. Li ◽  
T. Zhang ◽  
X.H. Yang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Cutting Speed ◽  
Element Model ◽  
Stress Generation ◽  
Workpiece Surface ◽  
Mechanical Coupling ◽  
Basic Parameters

Mathematical models of basic parameters, force and thermal parameters of cutting were obtained by applying the thermo-elastic-plastic theory and the heat-balance theory, according to the principle of residual stress generation in cutting process. Based on the 2D finite element model of chip molding with separation surface, the direct way was applied in thermo-mechanical coupling, and residual stress of cutting GH4169 were simulated and analyzed by finite element. The results showed that the residual stresses are changed from tensile to compressive with the development of depth away from the workpiece surface. Also its values are changed according to a certain rule as varying the cutting speed. These provide a foundation for the control of cutting quality of workpiece.

scholarly journals Targeted residual stress generation in single and two point incremental sheet forming (ISF)

2021 ◽  
Author(s):  
Fawad Maqbool ◽  
Fabian Maaß ◽  
Johannes Buhl ◽  
Marlon Hahn ◽  
Ramin Hajavifard ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Incremental Forming ◽  
Incremental Sheet Forming ◽  
Generation Mechanism ◽  
Stress Generation ◽  
Process Variants ◽  
Residual Stress State

AbstractThe mechanical properties and the operating life of a formed component are highly dependent on the residual stress state. There is always a high magnitude of residual stresses in the components formed by incremental sheet forming (ISF) due to the localized deformation mechanism. Hence, a thorough understanding of the generation of the residual stresses by ISF is necessary. This study investigates the residual stress generation mechanism for two process variants of ISF, i.e., Single Point Incremental Forming (SPIF) and Two Point Incremental Forming (TPIF). This understanding is used to control and targetedly generate the residual stresses to improve the part performance. In this regard, the residual stress state in a truncated cone geometry manufactured using SPIF and disc springs manufactured using TPIF was experimentally analyzed. Validated numerical models for both process variants were developed to study the residual stresses in detail. The residual stress state in SPIF is such that the tool contact side develops tensile residual stresses and the non-contact side undergoes compressive residual stresses. The tool step-down variation was used to control residual stresses and improve the fatigue strength of truncated cones manufactured using SPIF. For TPIF, two different forming strategies were used to analyze the residual stress generation mechanism and the role of major process parameters. The residual stresses for TPIF are pre-dominantly compressive in both directions of forming tool motion. For both process variants of the ISF process, it is shown that the residual stresses can be beneficially utilized to improve mechanical properties of the components.

Modeling of residual stresses by correlating surface topography in machining of AISI 52100 steel

2021 ◽  
pp. 1-26
Author(s):  
Chao Liu ◽  
Yan He ◽  
Yufeng Li ◽  
Yulin Wang ◽  
Shilong Wang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Force ◽  
Surface Topography ◽  
Analytical Model ◽  
Analytical Models ◽  
Workpiece Surface ◽  
Dynamic Cutting Force ◽  
Intermittent Cutting ◽  
Effect Of Surface

Abstract The residual stresses could affect the ability of components to bear loading conditions and also the performance. The researchers considered workpiece surface as a plane and ignored the effect of surface topography induced by the intermittent cutting process when modeling residual stresses. The aim of this research develops an analytical model to predict workpiece residual stresses during intermittent machining by correlating the effect of surface topography. The relative motions of tool and workpiece are analyzed for modeling thermal-mechanical and surface topography. The influence of dynamic cutting force and thermal on different positions of surface topography is also considered in analytical model. Then the residual stresses model with the surface topography effect can be developed in intermittent cutting. The analytical models of dynamic cutting force, surface topography and residual stresses are verified by the experiments. The variation trend of evaluated values of the residual stress of workpiece is basically consistent with that of measured values. The compressive residual stress of workpiece surface in highest point of the surface topography are higher than that in the lowest point.

About Residual Stress State of Castings: The Case of HPDC Parts and Possible Advantages through Semi-Solid Processes

2022 ◽  
Vol 327 ◽  
pp. 272-278
Author(s):  
Elisa Fracchia ◽  
Federico Simone Gobber ◽  
Claudio Mus ◽  
Yuji Kobayashi ◽  
Mario Rosso
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Casting Process ◽  
Ray Method ◽  
Premature Failure ◽  
Thin Walls ◽  
Residual Stress State ◽  
Semi Solid ◽  
Pressure Die Casting

Nowadays, one of the most crucial focus in the aluminium-foundry sector is the production of high-quality castings. Mainly, High-Pressure Die Casting (HPDC) is broadly adopted, since by this process is possible to realize aluminium castings with thin walls and high specific mechanical properties. On the other hand, this casting process may cause tensile states into the castings, namely residual stresses. Residual stresses may strongly affect the life of the product causing premature failure of the casting. Various methods can assess these tensile states, but the non-destructive X-Ray method is the most commonly adopted. Namely, in this work, the residual stress analysis has been performed through Sinto-Pulstec μ-X360s. Detailed measurements have been done on powertrain components realized in aluminium alloy EN AC 46000 through HPDC processes to understand and prevent dangerous residual stress state into the aluminium castings. Furthermore, a comparison with stresses induced by Rheocasting processes is underway. In fact, it is well known that Semi-Solid metal forming combines the advantages of casting and forging, solving safety and environmental problems and possibly even the residual stress state can be positively affected.

scholarly journals Influence of a modified drawing process on the resulting residual stress state of cold drawn wire

2018 ◽  
Vol 190 ◽  
pp. 04004
Author(s):  
Markus Baumann ◽  
Alexander Graf ◽  
René Selbmann ◽  
Katrin Brömmelhoff ◽  
Verena Kräusel ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Wire Drawing ◽  
Industrial Applications ◽  
Drawing Process ◽  
Die Geometry ◽  
Residual Stress State ◽  
Drawing Die ◽  
Process Modification ◽  
The Wire

Torsion bars are used in automotive engineering as well as in other industrial applications. Such elements are produced by bending cold drawn wires. In conventional drawing processes tensile residual stresses occur near the surface of the wire. Small bending radii, which are required in limited assembly spaces, result in component failure due to reduced formability. Additional operations such as heat treatment or shot peening are necessary to influence the residual stress of the wire and to improve the dynamic stability of the torsion bar. The aim of the research is to reduce tensile residual stresses near the surface of the wire in order to eliminate process steps and to enhance formability. Therefore, a forming technology is developed by using a modified drawing die geometry on the basis of gradation extrusion. Finite element simulation is used to investigate the influences of element geometry, number of elements and process modification on the resulting residual stresses after wire drawing of a steel alloy. The results are evaluated and compared with the conventional wire drawing process. Furthermore, the requirements for the design of an experimental test device will be outlined as well as the measurement of the residual stresses by using X-ray diffraction.

Relaxation of Residual Stresses in Bearing Rings Based on the Optimal Geometric Setup of Equipment for Centerless Running

2019 ◽  
Vol 973 ◽  
pp. 183-188
Author(s):  
Albert V. Korolev ◽  
Andrei F. Balayev ◽  
Boris M. Iznairov
Keyword(s):  
Mathematical Model ◽  
Residual Stress ◽  
Stress Relaxation ◽  
Residual Stresses ◽  
Elastic Strain ◽  
New Approach ◽  
Technological Method ◽  
Residual Stress Relaxation ◽  
Bearing Rings

This paper discusses the technological method of residual stress relaxation of bearing rings by centerless running with cylindrical rolls. Described a new approach to relieve residual stresses by centerless running of elastically-deforming rolls on the basis of the geometrical setup of the equipment. It was found that geometrical setup of the equipment influences an elastic strain of parts and the degree of residual stress relaxation. We obtained a mathematical model for calculation of setup parameters to ensure the required variation value of elastic strain of the part. The results of experiments confirm the influence of the geometric setup on the magnitude of residual stress relaxation.

Modelling shattered rim cracking in railroad wheels

2011 ◽  
Vol 225 (6) ◽  
pp. 593-604
Author(s):  
V Sura ◽  
S Mahadevan
Keyword(s):  
Residual Stress ◽  
Stress Intensity Factor ◽  
Finite Element ◽  
Stress Intensity ◽  
Stress State ◽  
Intensity Factor ◽  
Residual Stresses ◽  
Equivalent Stress ◽  
Crack Tip ◽  
Residual Stress State

Shattered rim cracking, propagation of a subsurface crack parallel to the tread surface, is one of the dominant railroad wheel failure types observed in North America. This crack initiation and propagation life depends on several factors, such as wheel rim thickness, wheel load, residual stresses in the rim, and the size and location of material defects in the rim. This article investigates the effect of the above-mentioned parameters on shattered rim cracking, using finite element analysis and fracture mechanics. This cracking is modelled using a three-dimensional, multiresolution, elastic–plastic finite element model of a railroad wheel. Material defects are modelled as mathematically sharp cracks. Rolling contact loading is simulated by applying the wheel load on the tread surface over a Hertzian contact area. The equivalent stress intensity factor ranges at the subsurface crack tips are estimated using uni-modal stress intensity factors obtained from the finite element analysis and a mixed-mode crack growth model. The residual stress and wheel wear effects are also included in modelling shattered rim cracking. The analysis results show that the sensitive depth below the tread surface for shattered rim cracking ranges from 19.05 to 22.23 mm, which is in good agreement with field observations. The relationship of the equivalent stress intensity factor (Δ K eq) at the crack tip to the load magnitude is observed to be approximately linear. The analysis results show that the equivalent stress intensity factor (Δ K eq) at the crack tip depends significantly on the residual stress state in the wheel. Consideration of as-manufactured residual stresses decreases the Δ K eq at the crack tip by about 40 per cent compared to that of no residual stress state, whereas consideration of service-induced residual stresses increases the Δ K eq at the crack tip by about 50 per cent compared to that of as-manufactured residual stress state. In summary, the methodology developed in this article can help to predict whether a shattered rim crack will propagate for a given set of parameters, such as load magnitude, rim thickness, crack size, crack location, and residual stress state.

Study on the Residual Stress Induced by Dry Turning of Buttress Thread

2009 ◽  
Vol 69-70 ◽  
pp. 505-509
Author(s):  
X.Y. Wang ◽  
Qing Long An ◽  
Yun Shan Zhang ◽  
H. Xu ◽  
Ming Chen
Keyword(s):  
Residual Stress ◽  
Great Influence ◽  
Cutting Parameters ◽  
Element Model ◽  
Rake Angle ◽  
Pipe Material ◽  
Workpiece Surface ◽  
Dry Turning ◽  
Tool Geometries ◽  
High Temperature High Pressure

Stainless 2Cr13 is used as petroleum pipe material for its good performance in condition of high temperature, high pressure and corrosive environment. Buttress thread turning is a type of heavy machining, which has a great influence on the residual stress of workpiece. Residual stress is usually determined by cutting parameters and tool geometries. Experiments with different geometrical tools were carried out and a finite element model was used to study the influence of tool geometries on the residual stress. Experimental and simulated results showed that relatively bigger rake angle and smaller corner radius make a relatively lower tensile residual stress of workpiece surface in dry turning buttress thread.

A Detailed Evaluation of the Effects of Bulk Residual Stress on Fatigue in Aluminum

2014 ◽  
Vol 891-892 ◽  
pp. 1205-1211 ◽  
Author(s):  
Dale L. Ball ◽  
Mark A. James ◽  
Robert J. Bucci ◽  
John D. Watton ◽  
Adrian T. DeWald ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Effective Utilization ◽  
Stress Effects ◽  
The Past ◽  
Property Data ◽  
Design Cycle ◽  
Detailed Evaluation ◽  
The Impact

The fully effective utilization of large aluminum forgings in aerospace structures has been hampered in the past by inadequate understanding of, and sometimes inaccurate representation of, bulk residual stresses and their impact on both design mechanical properties and structural performance. In recent years, significant advances in both computational and experimental methods have led to vastly improved characterization of residual stresses. As a result, new design approaches which require the extraction of residual stress effects from material property data and the formal inclusion of residual stresses in the design analysis, have been enabled. In particular, the impact of residual stresses on durability and damage tolerance can now be assessed, and more importantly, accounted for at the beginning of the design cycle.

Influence of Cooling Intensity on Residual Stress State of TIG Dressing Zone for T-Joint Welded Toe

2011 ◽  
Vol 148-149 ◽  
pp. 1289-1294 ◽  
Author(s):  
Kun Zhou ◽  
Chun Yuan Shi ◽  
Cheng Jin
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Stress State ◽  
Residual Stresses ◽  
Residual Stress Distribution ◽  
Residual Stress State ◽  
Cooling Intensity ◽  
Stress Layer ◽  
Spray Treatment

Using finite element method, the residual stress distribution of the TIG dressed welded toe followed by spray treatment with different cooling intensity was calculated. And the residual stresses of welded toe were also measured by using the blind-hole method. The results indicate that with the increase of cooling intensity, the longitudinal residual stresses in welded toe are gradually transited from tensile residual stresses to compressive ones, and there is no significant change for transverse residual stresses, and the depth of compressive stress layer increases at the welded toe region.

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