Study on the Correlativity between Grinding Parameters and Surface Residual Stresses in Ceramic

2008 ◽  
Vol 375-376 ◽  
pp. 480-484 ◽  
Author(s):  
Guang Xiu Zhang ◽  
Bin Lin ◽  
Zhen Peng Shi
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Mechanical Effect ◽  
Diffraction Measurement ◽  
Depth Of Penetration ◽  
Surface Residual Stress ◽  
Grinding Parameters ◽  
Surface Residual Stresses ◽  
Element Simulation

The generation and distribution of workpiece surface and sub-surface residual stress were predicted through the dynamic finite element simulation of the grinding ceramic process. The base of the simulation is that the thermo elastic-plastic finite element theory and the coupling of grinding forces and temperature were adopted. The results obtained from X-ray diffraction measurement compared well with the values calculated from theory. The correlation between grinding parameters and the ceramic residual stresses was investigated. The research results show that the normal grinding force is the primary factor responsible for the generation of residual stress in grinding ceramic. The mechanical effect of the grains is to affect the magnitude, the depth of penetration and the gradient of the residual stresses.

Micro-slotting technique for reliable measurement of sub-surface residual stress in Ti-6Al-4V

2018 ◽  
Vol 53 (6) ◽  
pp. 389-399 ◽  
Author(s):  
Elizabeth Burns ◽  
Joseph Newkirk ◽  
James Castle
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Image Correlation ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Near Surface ◽  
X Ray ◽  
Measurement Volume ◽  
Surface Residual Stresses

Micro-slotting, a relaxation residual stress measurement technique, has recently been shown to be an effective method for measuring local residual stresses in a variety of materials. The micro-slotting method relies on a scanning electron microscope–focused ion beam system for milling and imaging, digital image correlation software to track displacements due to residual stress relaxation after milling, and finite element analysis for displacement–stress correlation and calculation of the original stress state in the imaged region. The high spatial resolution of the micro-slotting method makes it a promising technique for obtaining near-surface residual stress data in Ti-6Al-4V components for input into fatigue life models and crack growth simulations. However, use of the micro-slotting method on this alloy has yet to be evaluated against more established measurement techniques. In this study, spatially resolved sub-surface residual stress measurements were obtained on shot peened and low-stress surface-machined Ti-6Al-4V planar coupons using the micro-slotting method and were compared to measurements obtained using the conventional X-ray diffraction depth profiling technique. The sub-surface measurements were in good agreement for the shot peened sample. Observed differences in the measured near-surface residual stresses on the surface-machined sample were attributed to the larger measurement volume of the X-ray diffraction method, suggesting that the micron-sized measurement volume of the micro-slotting method may be more suitable for capturing shallow stress profiles and steep stress gradients. Prior to performing the micro-slotting measurements, finite element modeled displacements were used to verify the measurement procedure and to address uncertainties in the milled slot geometries. The results of this study demonstrated the validity of the micro-slotting procedure and established the technique as a reliable method for measuring sub-surface residual stresses in Ti-6Al-4V.

Modeling and Prediction of Residual Stresses in Additive Layer Manufacturing by Microplasma Transferred Arc Process Using Finite Element Simulation

2019 ◽  
Vol 141 (6) ◽  
Author(s):  
Sagar H. Nikam ◽  
N. K. Jain
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Temperature Distribution ◽  
Residual Stresses ◽  
Substrate Material ◽  
Tensile Residual Stress ◽  
Additive Layer Manufacturing ◽  
Element Simulation ◽  
Layer Manufacturing ◽  
Transferred Arc

Prediction of residual stresses induced by any additive layer manufacturing process greatly helps in preventing thermal cracking and distortion formed in the substrate and deposition material. This paper presents the development of a model for the prediction of residual stresses using three-dimensional finite element simulation (3D-FES) and their experimental validation in a single-track and double-track deposition of Ti-6Al-4V powder on AISI 4130 substrate by the microplasma transferred arc (µ-PTA) powder deposition process. It involved 3D-FES of the temperature distribution and thermal cycles that were validated experimentally using three K-type thermocouples mounted along the deposition direction. Temperature distribution, thermal cycles, and residual stresses are predicted in terms of the µ-PTA process parameters and temperature-dependent properties of substrate and deposition materials. Influence of a number of deposition tracks on the residual stresses is also studied. Results reveal that (i) tensile residual stress is higher at the bonding between the deposition and substrate and attains a minimum value at the midpoint of a deposition track; (ii) maximum tensile residual stress occurs in the substrate material at its interface with deposition track. This primarily causes distortion and thermal cracks; (iii) maximum compressive residual stress occurs approximately at mid-height of the substrate material; and (iv) deposition of a subsequent track relieves tensile residual stress induced by the previously deposited track.

The Characteristics of Surface Residual Stresses by Plane Grinding Invar and the Effects of Them on Structural Stability

2008 ◽  
Vol 53-54 ◽  
pp. 293-298
Author(s):  
Y.P. Qiao ◽  
Ren Ke Kang ◽  
Zhu Ji Jin ◽  
Dong Ming Guo
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Residual Stresses ◽  
Structure Stability ◽  
Tension Stress ◽  
Surface Residual Stress ◽  
Disk Model ◽  
Surface Residual Stresses ◽  
The Stability ◽  
Working Procedure

Invar 36 alloy is widely used in manufacturing instruments because of its minimal thermal expansion coefficient. As an important material for the components of precision or super-precision instruments, the process methods for Invar and the structure stability after its machining is necessary. In this paper, the residual stresses of the Invar samples after plane grinding were measured. The experimental results indicate that clear tension stress exists in the surface of Invar alloy along the grinding direction, while, on the cross direction, the states of surface residual stresses are complicated and affected by the parameters of grinding. A typical disk model has been calculated and analyzed by Finite Element Method (FEM), and the deformation caused by surface residual stress was presented. Finally, the effect of grinding as final working procedure on the stability of Invar structure was estimated.

Determination of surface residual stresses in carburised AISI 8620 steel by the magnetic Barkhausen noise method

2020 ◽  
Vol 62 (7) ◽  
pp. 416-421
Author(s):  
T Kaleli ◽  
C Hakan Gür
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Fatigue Behaviour ◽  
Barkhausen Noise ◽  
Magnetic Barkhausen Noise ◽  
Surface Residual Stress ◽  
Technical Requirements ◽  
Surface Residual Stresses

Management of the residual stress state is vital for the design and production stages of carburised components in order to satisfy the technical requirements related to performance, fatigue behaviour and useful lifetime. This enforces the use of practical, reliable and time- and cost-effective stress measurement methods by manufacturers. This study aims to investigate the efficiency of the magnetic Barkhausen noise (MBN) method in rapid non-destructive determination of surface residual stresses in carburised steels. A series of AISI 8620 steel specimens with different residual stress states was prepared by altering the carburising and subsequent tempering parameters. The specimens were characterised through scanning electron microscopy (SEM) investigations and hardness measurements, and the surface residual stresses were determined using both the MBN and X-ray diffraction (XRD) methods. The results show that a good correlation exists between surface residual stress and the parameters derived from the MBN signals.

Clamping Effect on the Welding Deformations in Dissimilar Welded Pipes (Joints) With Varied Thicknesses: Axial and Radial Shrinkage

2020 ◽  
Author(s):  
Bridget Kogo ◽  
Bin Wang ◽  
Mahmoud Chizari
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Simulation ◽  
Stress Measurement ◽  
Vertical Displacement ◽  
Hole Drilling ◽  
Element Simulation ◽  
Radial Shrinkage ◽  
Ultrasonic Stress Measurement

Abstract This study investigates and evaluates the welding residual stresses and deformations in the dissimilar material MSSS metals in order to verify the clamping effect on the residual stresses and deformations and entails comparison with the finite element simulation, the critically reflected longitudinal ultrasonic stress measurement and the hole-drilling residual stresses in a Butt-welded plate courtesy of Javadi et al [1]. The angular shrinkage measurement and vertical displacement were used to achieve this objective. The outcome of the study proved that the measurement of residual stress using protractor is an effective way of differentiating the influence of clamps on the longitudinal stresses.

Finite Element Simulation of Residual Stress on the Surface in the Cutting Considering Tool Flank Wear

2010 ◽  
Vol 431-432 ◽  
pp. 338-341
Author(s):  
Hai Tao Liu ◽  
Ya Zhou Sun ◽  
Ze Sheng Lu
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Finite Element Simulation ◽  
Flank Wear ◽  
Great Influence ◽  
Machining Accuracy ◽  
Surface Residual Stress ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Element Simulation

Deformation caused by residual stress has been one of the main reasons influencing the machining accuracy, studies on machining residual stress should be performed. The tool flank wear on the cutting process has great influence on cutting heat which will infulence the distribution of residual stress, therefore,we should do the finite element simulation of cutting tool flank wear on the heat-affected firstly,then simulate and forecast the surface residual stress, studies on the effect of tool flank wear on the distribution of machined surface residual stress Johnson-Cook’s coupled thermal-mechanical model is used as workpiece material model, thermal-displacement coupled brick are used to mesh, while friction between tool and work piece uses modified Coulomb's law whose slide friction area is combined with sticking friction. By means of FEA, residual stress on the machined surface and cutting temperature under different tool flank wear conditions are obtained. The results are compared and analyzed, and then we can get the fundamental influencing law on machined surface residual stress of tool flank wear.

Determination of Repair Weld Residual Stress in a Tube to Tube-Sheet Joint by Neutron Diffraction and the Finite Element Method

2018 ◽  
Vol 140 (2) ◽  
Author(s):  
Yun Luo ◽  
Wenchun Jiang ◽  
Dongfeng Chen ◽  
Robert C. Wimpory ◽  
Meijuan Li ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Diffraction Measurement ◽  
Neutron Diffraction Measurement ◽  
Repair Welding ◽  
Welding Direction ◽  
Element Method

Repair welding is a popular method to repair the leakage zone in tube-to-tubesheet joint of shell-tube heat exchangers. But the repaired residual stresses are generated inevitably and have a great effect on stress corrosion cracking (SCC). In this paper, the effects of repair welding on residual stress were studied by finite element method (FEM) and neutron diffraction measurement. The original weld residual stresses calculated by FEM showed good agreement with neutron diffraction measurement results. After repair welding, the transverse residual stresses change very little while the longitudinal residual stresses are increased in the repair zone. In the nonrepair zone, both the transverse and longitudinal stresses are decreased. The repair welding times have little effect on residual stress distribution. With the increase of welding length and heat input, the residual stresses increase. Repair opposite to the original welding direction is recommended because the opposite welding direction minimizes the residual stresses.

scholarly journals Modification of Residual Stresses in Laser Additive Manufactured AlSi10Mg Specimens Using an Ultrasonic Peening Technique

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 455 ◽  
Author(s):  
Xiaodong Xing ◽  
Xiaoming Duan ◽  
Xiaojing Sun ◽  
Haijun Gong ◽  
Liquan Wang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Finite Element ◽  
Stress Distribution ◽  
Residual Stresses ◽  
Finite Element Simulation ◽  
Residual Stress Distribution ◽  
Ultrasonic Peening ◽  
Element Simulation ◽  
Before And After

Ultrasonic peening treatment (UPT) has been proved to be an effective way of improving residual stresses distribution in weld structures. Thus, it shows a great potential in stress modification for metal parts fabricated by additive manufacturing technology. In this paper, an investigation into the ultrasonic treatment process of AlSi10Mg specimens fabricated by selective laser melting (SLM) process was conducted by means of experimental and numerical simulation. The specimens were prepared using a SLM machine, and UPT on their top surface was carried out. The residual stresses were measured with an X-ray stress diffraction device before and after UPT. Meanwhile, a finite element simulation method for analyzing the influence of UPT on the residual stress field of specimens was proposed and validated by experiments. Firstly, the thermal mechanical coupling numerical simulation of the SLM process of the specimen was carried out in order to obtain the residual stress distribution in the as-fabricated specimen. Then, the transient dynamic finite element simulation model of the UPT process of the specimen was established, and the UPT effect analysis was implemented. In the UPT simulation, the residual stress was applied as a pre-stress on the specimen, and the specimen’s material mechanical property was described by the Johnson–Cook model, whose parameters were determined by Split Hopkinson Pressure Bar (SHPB) experiment. The residual stress distribution before and after UPT predicted by the finite element model agree well with the measurement results. This paper concludes with a discussion of the effects of ultrasonic peening time, as well as the frequency and amplitude of the peening needle on residual stress.

Bivariate Fourier-series-based prediction of surface residual stress fields using stresses of partial points

2018 ◽  
Vol 24 (4) ◽  
pp. 979-995 ◽  
Author(s):  
Fengyun Wang ◽  
Kuanmin Mao ◽  
Shanguo Wu ◽  
Bin Li ◽  
Gang Xiao
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Fourier Series ◽  
Stress Field ◽  
Residual Stresses ◽  
Initial Stresses ◽  
Stress Fields ◽  
Critical Parameters ◽  
Generation Process ◽  
Surface Residual Stress

Surface residual stresses are critical parameters for evaluating the surface quality and can have an influence on many mechanical properties of solids. These stresses inevitably arise in almost all engineering components during manufacturing. However, most experimental and finite element approaches cannot obtain a complete surface residual stress field in a mechanical part. In this study, we propose a predictive method to determine surface stress fields, depending on residual stresses being self-equilibrating. The effectiveness of the approach is verified using a numerical surface of a beam example with ideal measurements and a casting–milling surface with experimental data. Using the proposed method, surface residual stress fields can be obtained from the stresses of a limited number of points including boundary points to solve the governing equations via a Fourier series bivariate polynomial as an Airy stress function with the Tikhonov regularization method. Our method does not require simulations of the residual stress generation process. This method is suitable for complex engineering parts where the manufacturing process is difficult to recreate in detail. The predicted stress field can be imported into a finite element solver as initial stresses to promote the design, manufacturing, and assessment of mechanical components.

Weld Residual Stress in Tube to Tube Sheet Joints of a Heat Exchanger by Experimental and Finite Element Simulation

2016 ◽  
Vol 853 ◽  
pp. 306-310
Author(s):  
Yu Wan ◽  
Wen Chun Jiang ◽  
Jiang Bo Gao
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Heat Exchanger ◽  
Stress Distribution ◽  
Residual Stresses ◽  
Diffraction Measurement ◽  
Good Prediction ◽  
Tube Sheet ◽  
Central Surface ◽  
Weld Residual Stress

Shell-and-tube heat exchangers are widely used in petrol and petro-chemical industries. But weld residual stresses are generated in the tube-to-tube sheet joint and have a great effect on stress corrosion cracking. Therefore, a good prediction and an efficient evaluation of the weld residual stress are necessary to assure the structure integrity. In this work, X-ray diffraction measurement and finite element method have been used to study the residual stress distribution. The results show that the large tensile residual stresses, which have exceeded the yield stress, are generated in the tube to tube sheet joints, leading that the joints become the weakest parts of the heat exchanger. In the central surface part, a wave shape stress distribution is generated along the centerline of tube 1 and tube 3.

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