Robustness of Residual Stresses in Brake Discs by Metamodeling

2011 ◽  
Author(s):  
M. Hofwing
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Robustness Analysis ◽  
Element Model ◽  
Response Surfaces ◽  
Temperature History ◽  
Brake Disc ◽  
Finite Element Analyses ◽  
Brake Discs

During casting residual stresses are developed due to the solidification and cooling. In this work the robustness of residual stresses in casted brake discs with respect to variations in four parameters is evaluated. The parameters are Young’s modulus, yield strength and hardening, time of breaking the mould and the thickness of the brake disc. The robustness analysis is performed by Monte Carlo simulations of metamodels which are surrogates to a finite element model. Quadratic response surfaces and Kriging approximations are considered. Those are based on finite element analyses defined by a Latin hypercube sampled design of experiments. In the finite element analyses an un-coupled approach is utilized where a thermal analysis generates a temperature history of the solidification and cooling. Then follows a structural analysis which is driven by the temperature history. After casting the machining of the brake disc is analyzed by gradually removing elements in the finite element model. The results show that the variation in the studied parameters yield large variation in residual stresses. The thickness of the brake disc is the parameter that has largest influence to the variation in residual stresses. Furthermore, the level of the residual stresses are in general high and might influence the fatigue life of the brake disc.

A Finite Element Model of Orthogonal Metal Cutting

1985 ◽  
Vol 107 (4) ◽  
pp. 349-354 ◽  
Author(s):  
J. S. Strenkowski ◽  
J. T. Carroll
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Element Model ◽  
Effective Plastic Strain ◽  
Orthogonal Metal Cutting ◽  
Chip Separation ◽  
Chip Geometry

A finite element model of orthogonal metal cutting is described. The paper introduces a new chip separation criterion based on the effective plastic strain in the workpiece. Several cutting parameters that are often neglected in simplified metal-cutting models are included, such as elastic-plastic material properties of both the workpiece and tool, friction along the tool rake face, and geometry of the cutting edge and workpiece. The model predicts chip geometry, residual stresses in the workpiece, and tool stresses and forces, without any reliance on empirical metal cutting data. The paper demonstrates that use of a chip separation criterion based on effective plastic strain is essential in predicting chip geometry and residual stresses with the finite element method.

scholarly journals Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

2021 ◽  
pp. 146442072198974
Author(s):  
A Ktari ◽  
A Abdelkefi ◽  
N Guermazi ◽  
P Malecot ◽  
N Boudeau
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Plastic Flow ◽  
Tube Hydroforming ◽  
Three Dimensional ◽  
Element Model ◽  
Tube Cross Section ◽  
Straight Wall ◽  
Hydroforming Process

During tube hydroforming process, the friction conditions between the tube and the die have a great importance on the material plastic flow and the distribution of residual stresses of the final component. Indeed, a three-dimensional finite element model of a tube hydroforming process in the case of square section die has been performed, using dynamic and static approaches, to study the effect of the friction conditions on both plastic flow and residual stresses induced by the process. First, a comparative study between numerical and experimental results has been carried out to validate the finite element model. After that, various coefficients of friction were considered to study their effect on the thinning phenomenon and the residual stresses distribution. Different points have been retained from this study. The thinning is located in the transition zone cited between the straight wall and the corner zones of hydroformed tube due to the die–tube contact conditions changes during the process. In addition, it is clear that both die–tube friction conditions and the tube bending effects, which occurs respectively in the tube straight wall and corner zones, are the principal causes of the obtained residual stresses distribution along the tube cross-section.

Tube-to-Tubesheet Joints: Maximum Tensile Stress and Contact Pressure Due to Thermal Loading and Temperature Cycling

2002 ◽  
Author(s):  
Mahdi A. Allam ◽  
Andre Bazergui ◽  
Luc Marchand ◽  
Michel Derenne
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Contact Pressure ◽  
Thermal Loading ◽  
Element Model ◽  
Maximum Tensile Stress ◽  
Temperature Cycling ◽  
Operating Conditions ◽  
Service Reliability

Service reliability and durability of tubular heat exchangers and steam generators are much dependent on the proper response of the tube-to-tubesheet joints to the operating conditions. In this paper a 2-D axisymmetric finite element model is proposed and compared to a 3-D finite element solution for the purpose of predicting the temperature effect on the residual contact pressure and maximum tensile residual stresses of such joints. A parametric study using the finite element results shows that, although thermal loading and temperature cycling have a negligible effect on the maximum tensile residual stresses, the room-temperature initial residual contact pressure may be completely relieved following the initiation of plastic deformation in either the tube or the tubesheet during thermal loading. A comparison between the results of the proposed finite element model and those obtained from the literature shows good agreement. A simplified analytical approach, which may be used for the design of tube-to-tubesheet joints, is also proposed to predict the joint behavior at the operating conditions.

Accuracy and Robustness Analysis of Geometric Finite Element Model Updating Approach for Material Parameters Identification in Transient Dynamic

2018 ◽  
Vol 16 (01) ◽  
pp. 1850084 ◽  
Author(s):  
Clément Touzeau ◽  
Benoit Magnain ◽  
Quentin Serra ◽  
Éric Florentin
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Model Updating ◽  
Numerical Test ◽  
Robustness Analysis ◽  
Element Model ◽  
Finite Element Model Updating ◽  
Transient Dynamic ◽  
Material Parameters ◽  
Material Parameters Identification

We study the accuracy and the robustness of the Geometrical Finite Element Model Updating method proposed in Touzeau et al. [Touzeau, C., Magnain, B., Emile, B., Laurent, H. and Florentin, E. (2016) “Identification in transient dynamic using a geometry-based cost function in finite element model updating method,” Finite Elements Anal. Des. 122, 49–60]. In this work, the method is applied to transient dynamic in finite transformations to identify mechanical material parameters. A stochastic approach is performed to determine accuracy and robustness. The method is illustrated on numerical test cases and compared to a classical FEMU method. Uncertainties on the loading are taken into account in the identification using an original approach.

Effect of the uncertainty of multi-cut contour method and friction coefficient on residual stresses of constrained groove pressing process

2020 ◽  
pp. 095440622094890
Author(s):  
F Nazari ◽  
M Honarpisheh ◽  
H Zhao
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Element Model ◽  
Contour Method ◽  
Ultrafine Grained ◽  
First Pass ◽  
Uncertainty Of Results ◽  
Ultrafine Grained Microstructure

Constrained groove pressing (CGP) process is a severe plastic deformation (SPD) method that can create ultrafine-grained microstructure in the sheet metals. In this study, residual stresses of the CGP process and the effect of the friction coefficient on the residual stresses were investigated. The residual stresses were measured in two directions using a multi-cut contour method and a mathematical-finite element model was developed to estimate the uncertainty of results of the multi-cut contour method. In order to study the effect of the friction coefficient on the residual stresses, a 3D finite element model was employed and the results of it were validated with the experimental results of the CGP process. According to the results, residual stresses in the first pass of CGP are compressive on the surface and gradually change to tension at the center of the thickness. Investigation of the effect of the first cut on the residual stresses and uncertainty of the second cutting plane showed that the effect of the first cut is only confined to regions near the intersection of the two cuts. Distancing from the intersection of two cuts causes the effect of the first cut to be ineffective on the second cut. Also, evaluation of the effect of friction coefficient on the residual stress illustrated that friction has a direct relationship with the residual stresses.

Residual Stresses in Butt Welding of Two Circular Pipes: An Experimental and Numerical Investigation

2014 ◽  
Author(s):  
Gurinder Singh Brar
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Welding Process ◽  
Diffraction Method ◽  
Element Model ◽  
X Ray Diffraction ◽  
X Ray

Welding is a reliable and efficient joining process in which the coalescence of metals is achieved by fusion. Welding is carried out with a very complex thermal cycle which results in irreversible elastic-plastic deformation and residual stresses in and around fusion zone and heat affected zone (HAZ). A residual stress due to welding arises from the differential heating of the plates due to the weld heat source. Residual stresses may be an advantage or disadvantage in structural components depending on their nature and magnitude. The beneficial effect of these compressive stresses have been widely used in industry as these are believed to increase fatigue strength of the component and reduce stress corrosion cracking and brittle fracture. But due to the presence of residual stresses in and around the weld zone the strength and life of the component is also reduced. To understand the behavior of residual stresses, two 10 mm thick Fe410WC mild steel plates are butt welded using the Metal Active Gas (MAG) process. An experimental method (X-ray diffraction) and numerical analysis (finite element analysis) were then carried out to calculate the residual stress values in the welded plates. Three types of V-butt weld joint — two-pass, three-pass and four-pass were considered in this study. In multi-pass welding operation the residual stress pattern developed in the material changes with each weld pass. In X-ray diffraction method, the residual stresses were derived from the elastic strain measurements using a Young’s modulus value of 210 GPa and Poisson’s ratio of 0.3. Finite element method based, SolidWorks software was used to develop coupled thermal-mechanical three dimension finite element model. The finite element model was evaluated for the transient temperatures and residual stresses during welding. Also variations of the physical and mechanical properties of material with the temperature were taken into account. The numerical results for peak transverse residual stresses attained in the welded plates for two-pass, three-pass and four-pass welded joint were 67.7 N/mm2, 58.6 N/mm2, and 48.1 N/mm2 respectively. The peak temperature attained during welding process comes out to be 970°C for two-pass weld, 820.8°C for three-pass weld and 651.9°C for four-pass weld. It can be concluded that due to increase in the number of passes during welding process or deposition weld beads, the residual stresses and temperature distribution decrease. Also, the results obtained by finite element method agree well with those from experimental X-ray diffraction method.

Prediction and Testing (ASTM E-837-89) of Residual Stresses in Structures (Operated in SOHIC Environment) Caused by Welding

2002 ◽  
Author(s):  
Sasan Armand ◽  
Stan Jones
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Element Model ◽  
Structural Testing ◽  
Finite Element Technique ◽  
Stress Cracking ◽  
Failure Investigation ◽  
The Difference ◽  
Element Technique

The study and testing of the structural behavior of a failed pipe with a spiral weld seam was conducted. Our study and testing was part of a larger failure investigation to determine the influence of residual stress for initiation of hydrogen stress cracking. Finite element and structural testing methods were used to guide the study for determination of residual stresses. All properties used in our study were measured per ASTM A-370. The validation of the finite element model of the pipe was conducted against the test results per ASTM E-837-89. The difference in predicted and measured residual stresses was 3% at the ID of the structure. Due to the small differences in the results from analysis and testing, no correlation was required, and the test-validated finite element model was used to predict the total stresses due to the manufacturing processes and operational loads. Based on the validation results, one can conclude that the finite element technique is accurate for predicting residual welding stresses. The finite element technique, however, is far less time -consuming and thus less expensive method than mechanical testing for determining the residual stresses.

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