Analysis of Thermal Stresses and Residual Stress Changes in Railroad Wheels Caused by Severe Drag Braking

1977 ◽  
Vol 99 (1) ◽  
pp. 18-23 ◽  
Author(s):  
M. R. Johnson ◽  
R. E. Welch ◽  
K. S. Yeung
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Yield Point ◽  
Thermal Stresses ◽  
Material Behavior ◽  
Nonlinear Material ◽  
Residual Stress Field ◽  
Thermal Stress Field ◽  
Stress Changes ◽  
Railroad Wheels

A finite-element computer program, which takes into consideration nonlinear material behavior after the yield point has been exceeded, has been used to analyze the thermal stresses in railroad freight car wheels subjected to severe drag brake heating. The analysis has been used with typical wheel material properties and wheel configurations to determine the thermal stress field and the extent of regions in the wheel where the yield point is exceeded. The resulting changes in the residual stress field after the wheel has cooled to ambient temperature have also been calculated. It is shown that severe drag braking can lead to the development of residual circumferential tensile stresses in the rim and radial compressive stresses in the plate near both the hub and rim fillets.

Macro-Residual Stress Field Retrieval for Predicting the Machining Deformation of Non-Prestretched Plate

2011 ◽  
Vol 317-319 ◽  
pp. 386-392
Author(s):  
Yin Fei Yang ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Large Scale ◽  
Hole Drilling ◽  
Residual Stress Field ◽  
Hole Drilling Method ◽  
Machining Deformation ◽  
Stress Changes ◽  
Drilling Method ◽  
And Control

The unknown and uneven macro-residual stresses in blanks will cause deformation on large-scale component, especially in non-prestretched plates. Based on the retrieval of stress field by measuring stress changes due to the rebalance of stresses after machining, a new idea is proposed in this paper to predict and control the machining deformation of large-scale components. It consists of analysis of the machining deformation, retrieval of macro-residual stress field, and finally optimization of following cutting process. In the retrieval process, the stresses are measured with an improved hole-drilling method and the measured data are then interpolated to 3D stress field.

Stress Corrosion Cracking Analysis under Thermal Residual Stress Field Using S-FEM

2011 ◽  
Vol 462-463 ◽  
pp. 431-436 ◽  
Author(s):  
Masanori Kikuchi ◽  
Yoshitaka Wada ◽  
Yuto Shimizu ◽  
Yu Long Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Crack Growth ◽  
Fracture Behavior ◽  
Three Dimensional ◽  
Stress Fields ◽  
Crack Growth Behavior ◽  
Residual Stress Field ◽  
Energy Agency ◽  
Thermal Stress Field

Fracture in heat affected zone (HAZ) in welding has been a serious problem for the integrity of machines. Prediction of fracture behavior due to the residual stress field in HAZ is important. In this paper, S-Version FEM(S-FEM) is applied to simulate the crack growth under thermal and residual stress fields. For evaluation of stress intensity factor, virtual crack closure integral method (VCCM) is employed. In order to confirm the validity of this analysis, numerical results are compared with previously-reported analytical and experimental results. Then, crack growth analysis in piping structure with welding joint was conducted. The residual stress data was provided by JAEA, Japan Atomic Energy Agency, based on their numerical simulation. Using S-FEM, two- and three-dimensional analyses are conducted, and crack growth behavior under thermal stress field is studied and discussed.

Crack Growth Analysis in Weld-Heat Affected Zone Using S-Version FEM

2010 ◽  
Author(s):  
Masanori Kikuchi ◽  
Yoshitaka Wada ◽  
Yuto Shimizu ◽  
Yulong Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Crack Growth ◽  
Heat Affected Zone ◽  
Growth Analysis ◽  
Three Dimensional ◽  
Crack Growth Behavior ◽  
Residual Stress Field ◽  
Energy Agency ◽  
Thermal Stress Field

Fracture in the heat affected zone (HAZ) in welding has been a serious problem for the integrity of machines. Prediction of fracture behavior due to the residual stress field in HAZ is important. In this paper, the S-Version FEM(S-FEM) is applied to simulate the crack growth under thermal and residual stress fields. For evaluation of the stress intensity factor, the virtual crack closure integral method (VCCM) is employed. In order to confirm the validity of this analysis, numerical results are compared with previously reported analytical and experimental results. Then, a crack growth analysis in a piping structure with a welding joint was conducted. The residual stress data was provided by JAEA, Japan Atomic Energy Agency, based on their numerical simulation. Using S-FEM, two- and three-dimensional analyses are conducted, and crack growth behavior under thermal stress field is studied and discussed.

An Experimental-Numerical Determination of the Three-Dimensional Autofrettage Residual Stress Field Incorporating Bauschinger Effects

2005 ◽  
Vol 128 (2) ◽  
pp. 173-178 ◽  
Author(s):  
M. Perl ◽  
J. Perry
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Bauschinger Effect ◽  
Three Dimensional ◽  
Material Behavior ◽  
Numerical Code ◽  
Numerical Magnitude ◽  
Hydraulic Pressure ◽  
Numerical Representation ◽  
Residual Stress Field

Autofrettage of large-caliber gun barrels is used to increase the elastic strength of the tube and is based on the permanent expansion of the cylinder bore, using either hydraulic pressure or an oversized swage mandrel. The theoretical solution of the autofrettage problem involves different yield criteria, the Bauschinger effect, and the recalculation of the residual stress field post barrel’s machining. Accurate stress-strain data and their appropriate numerical representations are needed as input for the numerical analysis of the residual stress field due to autofrettage. The purpose of the present work is to develop a three-dimensional (3D) numerical solution for both the hydraulic and the swage autofrettage processes incorporating the Bauschinger effect, using an accurate numerical representation of the experimentally measured material behavior. The new 3D computer code that was developed is capable of determining the stresses, strains, displacements, and forces throughout the entire autofrettage process. The numerical results were validated by an instrumented standard swage autofrettage process. The numerical model was found to excellently reproduce the experimentally measured pushing force as well as the permanent bore enlargement of the barrel. The calculated tangential stresses and the measured ones follow a similar pattern, but their numerical magnitude differs considerably. A wide discrepancy in both pattern and magnitude was found between the calculated and the measured axial stresses. These discrepancies seem to stem from the exact details of the mandrel’s insertion into the tube and are now under further investigation. However, in order to further validate the numerical code an hydraulic autofrettage experiment will be performed, which will hopefully eliminate the swage autofrettage discrepancies.

Characterising Residual Stresses in Rectangular Beam Specimens Following Thermo-Mechanical Loading

2006 ◽  
Author(s):  
Ali Mirzaee-Sisan ◽  
Christopher E. Truman ◽  
David J. Smith
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Stress Field ◽  
Residual Stresses ◽  
Mechanical Loading ◽  
Ferritic Steel ◽  
Thermal Stresses ◽  
Residual Stress Field ◽  
Rectangular Beam

The neutron diffraction (ND) technique was used to characterise residual stress fields in thin rectangular beam specimens containing residual stresses induced thermo-mechanically by partial quenching. Two types of material were considered, type 316H stainless steel and A533B ferritic steel. The work was motivated by a need to investigate the influence of residual stress on the fracture behaviour of steels. During quenching, specimens experienced a severe temperature gradient which induced thermal stresses resulting in plastic strains and a subsequent residual stress field. An extensive finite element (FE) analysis was undertaken to predict the residual stress following thermo-mechanical loading. It was shown that partial quenching generated a considerable residual stress field in 316H stainless steel. However, the level of residual stresses in the A533B steel specimens was lower than that 316H stainless steel specimens. There was acceptable agreement between the finite element simulations and measurements with simulations generally predicting higher tensile residual stresses following partial quenching than those measured in the 316H stainless steel, and lower tensile residual stresses than those measured in the A533B ferritic steel.

The Evaluation of the 3-D Residual Stress Field Due to Hydraulic Autofrettage in a Finite Length Cylinder Incorporating the Bauschinger Effect Factor Based on the “Zero Offset Yield Stress”

2008 ◽  
Author(s):  
J. Perry ◽  
M. Perl
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Yield Stress ◽  
Yield Point ◽  
Finite Length ◽  
Bauschinger Effect ◽  
Residual Stress Field ◽  
Tangential Strain ◽  
Effect Factor ◽  
Zero Offset

The autofrettage process increases the ability of a pressurized cylinder to withstand higher pressure values prior to the onset of yielding. The yield-pressure of an autofrettaged cylinder is strongly affected by the Bauschinger Effect (BE) that results in a reduction of the yield stress in compression. This reduction, which is measured by the Bauschinger Effect Factor (BEF), highly depends on the exact determination of the yield point. The present analysis suggests a new 3-D axisymmetric model for solving the residual stress field in a hydraulically autofrettaged finite-length cylinder including the BEF curve evaluated by using the newly proposed concept of the “zero offset” yield point definition. The numerical model is validated experimentally using axial and tangential strain gauges attached to a thick walled cylinder undergoing hydraulic pressurization. The experimental set-up enables continuous strain measurements vs. the increasing pressure. The calculated strains and displacements as well as the initial yield-pressure were found to be in very good agreement with the measured values.

scholarly journals Residual stresses in thermite welded rails: significance of additional forging

2020 ◽  
Vol 64 (7) ◽  
pp. 1195-1212
Author(s):  
B. Lennart Josefson ◽  
R. Bisschop ◽  
M. Messaadi ◽  
J. Hantusch
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Residual Stresses ◽  
Weld Metal ◽  
Welding Process ◽  
Surface Zone ◽  
Fe Model ◽  
Uneven Surface ◽  
Residual Stress Field ◽  
High Dynamic

Abstract The aluminothermic welding (ATW) process is the most commonly used welding process for welding rails (track) in the field. The large amount of weld metal added in the ATW process may result in a wide uneven surface zone on the rail head, which may, in rare cases, lead to irregularities in wear and plastic deformation due to high dynamic wheel-rail forces as wheels pass. The present paper studies the introduction of additional forging to the ATW process, intended to reduce the width of the zone affected by the heat input, while not creating a more detrimental residual stress field. Simulations using a novel thermo-mechanical FE model of the ATW process show that addition of a forging pressure leads to a somewhat smaller width of the zone affected by heat. This is also found in a metallurgical examination, showing that this zone (weld metal and heat-affected zone) is fully pearlitic. Only marginal differences are found in the residual stress field when additional forging is applied. In both cases, large tensile residual stresses are found in the rail web at the weld. Additional forging may increase the risk of hot cracking due to an increase in plastic strains within the welded area.

A mechanism study on characteristic curve of residual stress field in Ti–6Al–4V induced by wet peening treatment

2015 ◽  
Vol 86 ◽  
pp. 761-764 ◽  
Author(s):  
Kang Li ◽  
Xue-song Fu ◽  
Rui-dong Li ◽  
Wen-long Zhou ◽  
Zhi-qiang Li
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Characteristic Curve ◽  
Mechanism Study ◽  
Residual Stress Field

Dynamic evolution of welding residual stress field under noncontact electromagnetic force

2010 ◽  
Vol 107 (5) ◽  
pp. 054904
Author(s):  
Da Xu ◽  
Xuesong Liu ◽  
Ping Wang ◽  
Jianguo Yang ◽  
Wei Xu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Electromagnetic Force ◽  
Welding Residual Stress ◽  
Dynamic Evolution ◽  
Residual Stress Field
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