Abstract: One of the most relevant phenomena in manufacturing is the residual stress state development through the manufacturing chain. In most cases, the residual stresses have their origin in the heterogenous plastification produced by the processes. Although a few manufacturing processes have been successfully approached by numerical modeling, there is still lack of understanding on how these processes' interactions will affect the final stress state. The objective of this work is to analyze the effect of the grinding procedure on the residual stress state generated by a quasi-static indentation. The model consists in a simplified approach of shot peening, modeling four cases with variations in indenter size and force. This model was validated through topography, measured by optical 3D focus-variation. The indentation model configured with two loads was then exposed to two grinding procedures and the result was analyzed. It was observed that the grinding procedure will have a significant effect on the stress state.
Abstract: Friction stir welding (FSW) is a joining process in the solid state, which eliminates problems associated with the material melting and solidification, such as cracks, residual stresses and distortions generated during conventional welding. Among the most important advantages of FSW are; easy automation, less distortion, lower residual stress and good mechanical properties in the joining region. FSW is a recent approach to metal joining and although originally intended for aluminum alloys, it is investigated in a variety of metallic materials. The basic concept of FSW is a rotating tool, made of non-consumable material, specially designed with a geometry consisting of a pin and a recess (shoulder). This tool is inserted as spinning on its axis at the adjoining edges of two sheets or plates to be joined and then it travels along the joining path line. The tool rotation axis defines an angle of inclination with which the components to be welded. This angle is used for receiving the material to be processed at the tool base and to promote the gradual forge effect imposed by the shoulder during the passage of the tool. This prevents the material plastic flow at the tool lateral, ensuring weld closure on the back of the pin. In this study, two 4 mm Kevlar® plates which were produced with the Kevlar® fabrics, are analyzed with COMSOL Multiphysics in order to investigate the weldability via FSW. Thereafter, some experimental investigation is done with an appropriate workbench in order to compare them with the analysis results.
Abstract: The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.
Abstract: The work is devoted to solving the problem of temperature stresses, caused by the heating point of the round plate. The plate is made of elastoplastic material, so the Prandtl-Reis model is used. A piecewise-linear condition of the Ishlinsky-Ivlev flow is taken as the loading surface, in which the yield stress depends on the temperature. Piecewise-linear conditions (Treska or Ishlinsky-Ivlev), in contrast to the Mises condition, make it possible to obtain solutions of the equilibrium equation in an analytical form. In the problem under consideration, using the conditions of Tresca, it is impossible to obtain a solution. This is due to the fact that the equation of equilibrium ceases to be satisfied when the two Tresca conditions are fulfilled at once. Using the conditions of plastic flow Ishlinsky-Ivlev allows one to solve the problem. At the same time, there are also no solutions on the edge of the Ishlinsky-Ivlev hexagon in the plane-stressed state. Therefore, the authors of the article propose to jump from the edge to the edge of the mine edge, which gives an opportunity to obtain an analytical solution. At the same time, there is also no solution on the edge of the Ishlinsky-Ivlev hexagon in a plane stressed state; therefore, in this paper, the authors of the article propose to jump from the side to the side of the mine edge, which gives an opportunity to receive an analytical solution. The paper compares solutions of the problem of plate thermal deformation. One of the solutions was obtained under the condition that the elastic moduli (Young's modulus, Poisson's ratio) which depend on temperature. The yield point is assumed to be parabolically temperature dependent. The main results of the comparisons are that the region of irreversible deformation is larger in the calculations obtained for solving the problem with constant elastic moduli. There is no repeated plastic flow in the solution of the problem with elastic moduli depending on temperature. The absolute value of the irreversible deformations is higher for the solution of the problem in which the elastic moduli are constant; there are also insignificant differences in the distribution of the residual stresses.
Abstract: Fibre reinforced concrete (FRC) has been widely used in industrial pavements and non-structural elements such as pipes, culverts, tunnels, and precast elements. The strengthening effect of fibres in the concrete matrix is achieved primarily due to the bridging effect of fibres at the crack interfaces. The workability of the concrete was reduced on addition of high percentages of steel fibres. The optimum percentage of addition of steel fibres varies with its aspect ratio. For this study, 1% addition of steel has resulted to be the optimum percentage for both Hooked and Crimped Steel Fibres and was added to the beam specimens. The fibres restrain efficiently the cracks and take up residual stresses beyond the cracking. In this sense, diagonal cracks are effectively stitched up by fibres crossing it. The failure of beams within the shear failure range changed from shear to flexure in the presence of sufficient steel fibre quantity. The shear strength is increased with the addition of steel fibres and had exceeded the enhancement obtained with the transverse reinforcement. However, such increase is not directly in proportion with the quantity of fibres used. Considering all the clarification made in the present experimental investigation, it is concluded that 1% of crimped steel fibres with an aspect ratio of 50 is the best type of steel fibres for replacement of transverse stirrups in high strength concrete beams when compared to the steel fibres with hooked ends.
Abstract: Due to the numerous advantages of steel corrugated
web girders, its application field is growing for bridges as well as for
buildings. The global stability behavior of such girders is
significantly larger than those of conventional I-girders with flat web,
thus the application of the structural steel material can be
significantly reduced. Design codes and specifications do not provide
clear and complete rules or recommendations for the determination of
the lateral torsional buckling (LTB) resistance of corrugated web
girders. Therefore, the authors made a thorough investigation
regarding the LTB resistance of the corrugated web girders. Finite
element (FE) simulations have been performed to develop new
design formulas for the determination of the LTB resistance of
trapezoidally corrugated web girders. FE model is developed
considering geometrical and material nonlinear analysis using
equivalent geometric imperfections (GMNI analysis). The equivalent
geometric imperfections involve the initial geometric imperfections
and residual stresses coming from rolling, welding and flame cutting.
Imperfection sensitivity analysis was performed to determine the
necessary magnitudes regarding only the first eigenmodes shape
imperfections. By the help of the validated FE model, an extended
parametric study is carried out to investigate the LTB resistance for
different trapezoidal corrugation profiles. First, the critical moment of
a specific girder was calculated by FE model. The critical moments
from the FE calculations are compared to the previous analytical
calculation proposals. Then, nonlinear analysis was carried out to
determine the ultimate resistance. Due to the numerical
investigations, new proposals are developed for the determination of
the LTB resistance of trapezoidally corrugated web girders through a
modification factor on the design method related to the conventional
flat web girders.
Abstract: In this investigation, a laser cladding process with a powder feeding was used to deposit stainless steel 410L (high strength, excellent resistance to abrasion and corrosion, and great laser compatibility) onto railhead (higher strength, heat treated hypereutectoid rail grade manufactured in accordance with the requirements of European standard EN 13674 Part 1 for R400HT grade), to investigate the development and controllability of process-induced residual stress in the cladding, heat-affected zone (HAZ) and substrate and to analyse their correlation with hardness profile during two different laser cladding directions (across and along the track). Residual stresses were analysed by neutron diffraction at OPAL reactor, ANSTO. Neutron diffraction was carried out on the samples in longitudinal (parallel to the rail), transverse (perpendicular to the rail) and normal (through thickness) directions with high spatial resolution through the thickness. Due to the thick rail and thin cladding, 4 mm thick reference samples were prepared from every specimen by Electric Discharge Machining (EDM). Metallography across the laser claded sample revealed four distinct zones: The clad zone, the dilution zone, HAZ and the substrate. Compressive residual stresses were found in the clad zone and tensile residual stress in the dilution zone and HAZ. Laser cladding in longitudinally cladding induced higher tensile stress in the HAZ, whereas transversely cladding rail showed lower tensile behavior.
Abstract: GJ steel is a new type of high-performance structural steel which has been increasingly adopted in practical engineering. Q460GJ structural steel has a nominal yield strength of 460 MPa, which does not decrease significantly with the increase of steel plate thickness like normal structural steel. Thus, Q460GJ structural steel is normally used in medium-walled welded sections. However, research works on the residual stress in GJ steel members are few though it is one of the vital factors that can affect the member and structural behavior. This article aims to investigate the residual stresses in welded I-shaped sections fabricated from Q460GJ structural steel plates by experimental tests. A total of four full scale welded medium-walled I-shaped sections were tested by sectioning method. Both circular curve correction method and straightening measurement method were adopted in this study to obtain the final magnitude and distribution of the longitudinal residual stresses. In addition, this paper also explores the interaction between flanges and webs. And based on the statistical evaluation of the experimental data, a multilayer residual stress model is proposed.
Abstract: In this paper, a two-dimensional method is developed to simulate the fillet welds in a stiffened cylindrical shell, using finite element method. The stiffener material is aluminum 2519. The thermo-elasto-plastic analysis is used to analyze the thermo-mechanical behavior. Due to the high heat flux rate of the welding process, two uncouple thermal and mechanical analysis are carried out instead of performing a single couple thermo-mechanical simulation. In order to investigate the effects of the welding procedures, two different welding techniques are examined. The resulted residual stresses and distortions due to different welding procedures are obtained. Furthermore, this study employed the technique of element birth and death to simulate the weld filler variation with time in fillet welds. The obtained results are in good agreement with the published experimental and three-dimensional numerical simulation results. Therefore, the proposed 2D modeling technique can effectively give the corresponding results of 3D models. Furthermore, by inspection of the obtained residual hoop and transverse stresses and angular distortions, proper welding procedure is suggested.
Abstract: Growth and remodeling of biological structures have
gained lots of attention over the past decades. Determining the
response of living tissues to mechanical loads is necessary for a wide
range of developing fields such as prosthetics design or computerassisted
surgical interventions. It is a well-known fact that biological
structures are never stress-free, even when externally unloaded. The
exact origin of these residual stresses is not clear, but theoretically,
growth is one of the main sources. Extracting body organ’s shapes
from medical imaging does not produce any information regarding
the existing residual stresses in that organ. The simplest cause of such
stresses is gravity since an organ grows under its influence from
birth. Ignoring such residual stresses might cause erroneous results in
numerical simulations. Accounting for residual stresses due to tissue
growth can improve the accuracy of mechanical analysis results. This
paper presents an original computational framework based on gradual
growth to determine the residual stresses due to growth. To illustrate
the method, we apply it to a finite element model of a healthy human
face reconstructed from medical images. The distribution of residual
stress in facial tissues is computed, which can overcome the effect of
gravity and maintain tissues firmness. Our assumption is that tissue
wrinkles caused by aging could be a consequence of decreasing
residual stress and thus not counteracting gravity. Taking into
account these stresses seems therefore extremely important in
maxillofacial surgery. It would indeed help surgeons to estimate
tissues changes after surgery.
Abstract: X-ray diffraction is an effective mean for analyzing material properties. This paper developed a new computational software for determining the properties of crystalline materials such as elastic constants, residual stresses, surface hardness, phase components, and etc. The results computed from the X-ray diffraction method were compared to those from the traditional methods and they are in the 95% confidential limits, showing that the newly developed software has high reproducibility, opening a possibility of its commercialization.
Abstract: In this paper fatigue crack initiation and propagation in notched plate under constant amplitude loading through tensile residual stress field of 2024 T351 Al-alloy plate were investigated. Residual stress field was generated by plastic deformation using finite element method (FEM) where isotropic hardening in Von Mises model was applied. Simulation of fatigue behavior was made on AFGROW code. It was shown that the fatigue crack initiation and propagation were affected by level of residual stress filed. In this investigation, the presence of tensile residual stresses at notch (hole) reduces considerably the total fatigue life. It was shown that the decreasing in stress reduces the fatigue crack growth rates.
Abstract: In this paper, the techniques for estimating the
residual stress in high velocity oxy fuel thermal spray coatings have
been discussed and compared. The development trend and the last
investigation have been studied. It is seemed that the there is not
effective study on the effect of the peening action in HVOF
analytically and numerically.
Abstract: The plastic forming process of sheet plate takes an
important place in forming metals. The traditional techniques of tool
design for sheet forming operations used in industry are experimental
and expensive methods. Prediction of the forming results,
determination of the punching force, blank holder forces and the
thickness distribution of the sheet metal will decrease the production
cost and time of the material to be formed. In this paper, multi-stage
deep drawing simulation of an Industrial Part has been presented
with finite element method. The entire production steps with
additional operations such as intermediate annealing and springback
has been simulated by ABAQUS software under axisymmetric
conditions. The simulation results such as sheet thickness
distribution, Punch force and residual stresses have been extracted in
any stages and sheet thickness distribution was compared with
experimental results. It was found through comparison of results, the
FE model have proven to be in close agreement with those of
experiment.
Abstract: Arc welding is an important joining process widely used in many industrial applications including production of automobile, ships structures and metal tanks. In welding process, the moving electrode causes highly non-uniform temperature distribution that leads to residual stresses and different deviations, especially buckling distortions in thin plates. In order to control the deviations and increase the quality of welded plates, a fixture can be used as a practical and low cost method with high efficiency. In this study, a coupled thermo-mechanical finite element model is coded in the software ANSYS to simulate the behavior of thin plates located by a 3-2-1 positioning system during the welding process. Computational results are compared with recent similar works to validate the finite element models. The agreement between the result of proposed model and other reported data proves that finite element modeling can accurately predict the behavior of welded thin plates.
Abstract: A thin layer on the component surface can be found
with high tensile residual stresses, due to turning operations, which
can dangerously affect the fatigue performance of the component. In
this paper an analytical approach is presented to reconstruct the
residual stress field from a limited incomplete set of measurements.
Airy stress function is used as the primary unknown to directly solve
the equilibrium equations and satisfying the boundary conditions. In
this new method there exists the flexibility to impose the physical
conditions that govern the behavior of residual stress to achieve a
meaningful complete stress field. The analysis is also coupled to a
least squares approximation and a regularization method to provide
stability of the inverse problem. The power of this new method is
then demonstrated by analyzing some experimental measurements
and achieving a good agreement between the model prediction and
the results obtained from residual stress measurement.
Abstract: In this paper, the residual stress of thermal spray
coatings in gas turbine component by curvature method has been
studied. The samples and shaft were coated by hard WC-12Co
cermets using high velocity oxy fuel (HVOF) after preparation in
same conditions. The curvature of coated samples was measured by
using of coordinate measurement machine (CMM). The metallurgical
and Tribological studies has been made on the coated shaft using
optical microscopy and scanning electron microscopy (SEM)
Abstract: In this paper, the strength of a stabilizer is determined when the static and fatigue multiaxial loading are applied. Stabilizer is a part of suspension system in the heavy truck for stabilizing the cabin against the vibration of the road which composes of a thin-walled tube joined to a forge component by fillet weld. The component is loaded by non proportional random sequence of torsion and bending. Residual stress of welding process is considered here for static loading. This static loading with road irregularities are applied in this study as fatigue case that can affected in the fillet welded area of this part. The stresses in the welded structure are calculated using FEA. In addition, the fatigue with multi axial loading in the fillet weld is also investigated and the critical zone of the stabilizer is specified and presented by graphs. Residual stresses that have been resulted by the thermal forces are considered in FEA. Force increasing is the element of finding the critical point of the component.
Abstract: A Vehicle-s door wireing harness arrangement structure is provided. In vehicle-s door wiring harness(W/H) system is more toward to arrange a passenger compartment than a hinge and a weatherstrip. This article gives some insight into the dimensioning process, with special focus on large deflection analysis of wiring harness(W/H) in vehicle-s door structures for durability problem. An Finite elements analysis for door wiring harness(W/H) are used for residual stresses and dimensional stability with bending flexible. Durability test data for slim test specimens were compared with the numerical predicted fatigue life for verification. The final lifing of the component combines the effects of these microstructural features with the complex stress state arising from the combined service loading and residual stresses.