Prediction of Residual Stress in Multi-Step Orthogonal Cutting

2015 ◽  
Author(s):  
Yamin Shao ◽  
Omar Fergani ◽  
Torgeir Welo ◽  
Steven Liang
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Fatigue Behavior ◽  
Orthogonal Cutting ◽  
Hardening Behavior ◽  
Model Predictions ◽  
Analytical Algorithm ◽  
Precision Part

The effect of residual stresses on the fatigue behavior as well as the dimensional stability of high precision part is very important. Machining operation consists generally multi-step operations from roughing to finishing. It is therefore critical to predict residual stresses under such configuration. In this paper, an analytical algorithm is proposed to predict the final residual stresses induced by a multi-step machining operation capturing the change of stress state of the workpiece as well as material hardening behavior during the multi-step orthogonal cutting. The model predictions were compared to other work’s finite element method (FEM) predictions.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

Residual Stresses in Self-Curing Bone Cement During Hip Arthroplasty

2003 ◽  
Author(s):  
Chaodi Li ◽  
Ying Wang ◽  
James J. Mason
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Hip Arthroplasty ◽  
Experimental Tests ◽  
Cement Mantle ◽  
Joint Arthroplasty ◽  
Residual Stress Distribution ◽  
Bone Cements

Bone cements are widely used to fix prostheses into bones for joint arthroplasty. During cement curing in total hip arthroplasty, residual stresses are introduced in the cement mantle. A finite element method was developed to predict such residual stress built-up. The effects of curing history on the residual stress distribution were investigated. Results showed that the predictions of the residual stresses agreed with the experimental tests very well. The residual stress build-up was shown to depend on the curing history. By preheating the prosthesis stem prior to implantation, a desired low level residual stress at the critical interface was obtained.

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.

Modeling Residual Stresses in Superduplex Stainless Steel Welded Pipes Using the Finite Element Method

2013 ◽  
Vol 758 ◽  
pp. 1-10
Author(s):  
Fabiano Rezende ◽  
Luís Felipe Guimarães de Souza ◽  
Pedro Manuel Calas Lopes Pacheco
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Residual Stresses ◽  
Welding Process ◽  
Welding Parameters ◽  
Superduplex Stainless Steel ◽  
Mechanical Components ◽  
Element Method

Welding is a complex process where localized and intensive heat is imposed to a piece promoting mechanical and metallurgical changes. Phenomenological aspects of welding process involve couplings among different physical processes and its description is unusually complex. Basically, three couplings are essential: thermal, phase transformation and mechanical phenomena. Welding processes can generate residual stress due to the thermal gradient imposed to the workpiece in association to geometric restrictions. The presence of tensile residual stresses can be especially dangerous to mechanical components submitted to fatigue loadings. The present work regards on study the residual stress in welded superduplex stainless steel pipes using experimental and a numerical analysis. A parametric nonlinear elastoplastic model based on finite element method is used for the evaluation of residual stress in superduplex steel welding. The developed model takes into account the coupling between mechanical and thermal fields and the temperature dependency of the thermomechanical properties. Thermocouples are used to measure the temperature evolution during welding stages. Instrumented hole drilling technique is used for the evaluation of the residual stress after welding process. Experimental data is used to calibrate the numerical model. The methodology is applied to evaluate the behavior of two-pass girth welding (TIG for root pass and SMAW for finishing) in 4 inch diameter seamless tubes of superduplex stainless steel UNS32750. The result shows a good agreement between numerical experimental results. The proposed methodology can be used in complex geometries as a powerful tool to study and adjust welding parameters to minimize the residual stresses on welded mechanical components.

FEA of Residual Stresses in Butt Welded Type Low Carbon Steel Using MMAW Technique

2011 ◽  
Vol 110-116 ◽  
pp. 2686-2692
Author(s):  
Gurinder Singh Brar ◽  
Gurdeep Singh
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Carbon Steel ◽  
Residual Stresses ◽  
Low Carbon Steel ◽  
Pressure Vessels ◽  
Transient Temperature ◽  
Low Carbon ◽  
Element Method

Welding is a reliable and efficient joining process in which the coalescence of metals is achieved by fusion. Welding is widely employed in diverse structures such as ships, aircraft, marine structures, bridges, ground vehicles, pipelines and pressure vessels. When two dissimilar plates are joined by welding process, a very complex thermal cycle is applied to the weldment, which further causes inhomogeneous plastic deformation and residual stress in and around fusion zone and heat affected zone (HAZ). Presence of residual stresses may be beneficial or harmful for the structural components depending on the nature and magnitude of residual stresses. In this study, a finite element analysis has been carried out to analyze the thermo-mechanical behaviour and effect of residual stress state in butt-welded in low carbon steel plates. A coupled thermal mechanical three dimension finite element model was developed. Finite element method based software SolidWorks Simulation, was then used to evaluate transient temperature and residual stress during butt welding of two plates. Plate thickness of 8 mm were used which are normally joined by multi-pass operation by Manual Metal Arc Welding (MMAW) process. During each pass, attained peak temperature and variation of residual stresses in plates has also been studied. The results obtained by finite element method agree well with those from X-ray diffraction method as published by Murugan et al. for the prediction of residual stresses.

Influence of Initial Temperature of Chilling Treatment on Residual Stress State of TIG Dressing Zone for T-Joint Welded Toe

2012 ◽  
Vol 268-270 ◽  
pp. 529-533
Author(s):  
Chun Yuan Shi ◽  
Ping Zhu ◽  
Kun Zhou
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Residual Stresses ◽  
Initial Temperature ◽  
Residual Stress Distribution ◽  
Residual Stress State ◽  
Significant Change ◽  
Chilling Treatment

Using finite element method, the residual stress distribution of TIG dressed welded toe followed by chilling treatment with different temperature of steel and aluminum alloy T-joint 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 initial temperature of chilling treatment, the longitudinal residual stresses in welded toe of steel joint are gradually transited from tensile residual stresses to compressive ones, and there is no significant change for transverse residual stresses; and the longitudinal residual stresses in welded toe of aluminum alloy joint are compressive stress and gradually increased, no significant change for transverse residual stresses.

Laminated Ceramic Structures within Alumina / YTZP System Obtained by Low Pressure Joining

2007 ◽  
Vol 333 ◽  
pp. 219-222 ◽  
Author(s):  
Jonas Gurauskis ◽  
Antonio Javier Sanchez-Herencia ◽  
Carmen Baudín
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Material Properties ◽  
Layered Materials ◽  
Processing Parameters ◽  
Spectroscopic Technique ◽  
Reinforcement Mechanism ◽  
Laminated Structures

The production of multilayer ceramics by laminating stacked green ceramic tapes is one of the most attractive methods to fabricate layered materials. In this work, a new lamination technique was employed to obtain laminated ceramic structures in the aluminazirconia system with residual stress compression at the outer layers. This reinforcement mechanism would lead to ceramics with changed material properties and R-curve behaviour. The optimization of processing parameters for fabrication of defect free monolithic and laminated structures is described. The residual stresses developed in the laminated structures are discussed in terms of the results obtained from piezo-spectroscopic technique measurements and finite element method calculations.

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 of Residual Stresses in Butt Welded Plates Using Inherent Strains

1993 ◽  
Vol 115 (4) ◽  
pp. 417-423 ◽  
Author(s):  
Y. Ueda ◽  
M. G. Yuan
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
The Finite Element Method ◽  
Butt Weld ◽  
Butt Welds ◽  
Plastic Analysis ◽  
Inherent Strain ◽  
Element Method

The source of residual stresses in the vicinity of a weld may be expressed in terms of inherent strains. The characteristics of the inherent strain distributions in butt welds are investigated. It is found that the patterns vary little with changes in the welding conditions and sizes of the welded plates. With some assumptions, simple formulas are derived for the distribution and magnitude of inherent strain in a butt weld. A method of predicting the residual stress in a butt-welded plate using the characteristics of inherent strain distributions is presented. The validity of the method is confirmed by thermal elasto-plastic analysis using the finite element method (FEM).

scholarly journals Modeling and Calculating of Residual Stress and Strain of Butt Welded Joint

2021 ◽  
Vol 31 (5) ◽  
pp. 58-67
Keyword(s):  
Finite Element Method ◽  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Welded Joint ◽  
The Finite Element Method ◽  
Force Method ◽  
Stress Components ◽  
Residual Stresses And Strains ◽  
Element Method

The non-uniform thermal expansion and contraction resulting from welding processes cause residual stresses and strains. Experimental studies on measuring welding residual stresses and strains of structure are costly and sometimes they are not possible. Previously, analytical methods with idealized models were developed to determine the welding residual stresses and strain. Recently, numerical methods are constructed to analyze the stresses and the strains in welded structures. This paper presents the calculation results of residual stress and welding strain in butt welded joint of S355J2G3 carbon steel of 5 mm thickness made by MAG welding process with a single pass. The calculation is performed by two methods: the imaginary force method and the finite element method. In the finite element method, the SYSWELD software is used to simulate and to determine residual stresses and strain of this welded joint. The results of finite element method are compared with those of imaginary force method to show the rationality and the advantages of finite element method. The study results have shown that in this welded joint, only the longitudinal and transverse stress components are important and the other stress components are negligible.

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