scholarly journals Finite Element Analysis of Residual Stress in Ti-6Al-4V Alloy Plate Induced by Deep Rolling Process under Complex Roller Path

2014 ◽  
Vol 2014 ◽  
pp. 1-14 ◽  
Author(s):  
J. J. Liou ◽  
T. I. El-Wardany
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Reaction Force ◽  
Rolling Process ◽  
Surface Material ◽  
Deep Rolling ◽  
Alloy Plate ◽  
Near Surface ◽  
Material Recovery ◽  
Roller Path

The kinematics of the deep rolling tool, contact stress, and induced residual stress in the near-surface material of a flat Ti-6Al-4V alloy plate are numerically investigated. The deep rolling tool is under multiaxis nonlinear motion in the process. Unlike available deep rolling simulations in the open literature, the roller motion investigated in this study includes penetrative and slightly translational motions. A three-dimensional finite element model with dynamic explicit technique is developed to simulate the instantaneous complex roller motions during the deep rolling process. The initial motion of the rollers followed by the penetration motion to apply the load and perform the deep rolling process, the load releasing, and material recovery steps is sequentially simulated. This model is able to capture the transient characteristics of the kinematics on the roller and contacts between the roller and the plate due to variations of roller motion. The predictions show that the magnitude of roller reaction force in the penetration direction starts to decrease with time when the roller motion changes to the deep rolling step and the residual stress distributions in the near-surface material after the material recovery step varies considerably along the roller path.

Numerical Investigation of Lubricated Deep Rolling Process in a Complex Roller Path

2014 ◽  
Vol 966-967 ◽  
pp. 406-424
Author(s):  
Joe J. Liou ◽  
Tahany I. El-Wardany
Keyword(s):  
Residual Stress ◽  
Three Dimensional ◽  
Element Model ◽  
Rolling Process ◽  
Deep Rolling ◽  
Strain Rate Effects ◽  
Near Surface ◽  
Roller Path ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

Deep rolling process is a mechanical surface treatment that provides several advantages, such as low friction on the interface between the tool and workpiece in the process, controlled profile of induced compressive residual stress to enhance the HCF and LCF strength, enhancement of the stability of the near-surface structure at high temperature, and improvement of surface finish after the process. This paper investigates the deep rolling process under lubricated condition for a complex deep rolling path. A three-dimensional finite element model incorporating the strain hardening and strain rate effects on the material responses is developed to sequentially simulate the continuous multi-axis roller motion in the process. This model can capture the horizontal and normal forces acting on the roller so that a time-varying apparent coefficient of friction can be obtained. In addition, due to the complex roller path, the model also predicts a complex residual stress distribution in the near-surface material.

Effects of Deep Rolling on Surface Residual Stress and Microhardness of JIS SS400 MIG Welding

2018 ◽  
Vol 939 ◽  
pp. 31-37
Author(s):  
Adirek Baisukhan ◽  
Wasawat Nakkiew
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joint ◽  
Rolling Process ◽  
Rolling Speed ◽  
Mig Welding ◽  
Deep Rolling ◽  
Surface Microhardness ◽  
Rolling Pressure ◽  
Number Of Passes

Metal Inert Gas (MIG) welding process is a common welding process for carbon steels. During the cooling after welding, non-uniform cooling cause tensile residual stress on the surface of welded joint and, in most cases, in Heat Affected Zone (HAZ) also. The tensile residual stress is undesirable because it affects the strength and shorten the workpiece fatigue life. In order to convert the tensile residual stresses to desirable compressive residual stresses, the mechanical surface treatment like deep rolling process was used in this research. The surface residual stresses were measured by XRD machine with the sin2ψ method. For statistical analysis of significant factors used in deep rolling process, there are three factors each factor has two levels: rolling pressure, rolling speed and number of passes. Taguchi experimental design was used in conjunction with a deep rolling process to determine factors affected the surface residual stresses and surface microhardness. The results of the research showed that the most significant factors that affect the surface residual stress and surface microhardness were the number of passes, followed by the rolling pressure and the rolling speed, respectively. The maximum compressive residual stress measured at the welded joint was -521.5 MPa. The highest measured surface microhardness was 266.2 HV at the welded joint. The appropriated factors of deep rolling process for JIS SS400 MIG welding were rolling pressure 270 MPa, rolling speed 1,500 mm/min and number of passes 3 times.

Influence of Deep Rolling Process Parameters on Surface Residual Stress of AA7075-T651 Aluminum Alloy Friction Stir Welded Joint

2018 ◽  
Vol 939 ◽  
pp. 23-30 ◽  
Author(s):  
Adirek Baisukhan ◽  
Wasawat Nakkiew
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Residual Stresses ◽  
Compressive Residual Stress ◽  
Welded Joint ◽  
Rolling Process ◽  
Rolling Speed ◽  
Deep Rolling ◽  
Friction Stir ◽  
Rolling Pressure

Friction stir welding is most commonly used for joining aluminum alloy parts. After welding, residual stresses occurred in the welded joint caused by non-uniform cooling rate. Friction stir welding usually generates tensile residual stress inside the workpiece which affects the strength in addition to the fatigue life of materials. Compressive residual stress usually is beneficial and it can be introduced by mechanical surface treatment methods such as deep rolling, shot peening, laser shock peening, etc. In this research, deep rolling was used for inducing compressive residual stress on surface of friction stir welded joint. The residual stresses values were obtained from X-ray diffraction machine. Influence of three deep rolling process parameters: rolling pressure, rolling speed and rolling offset on surface residual stresses at the welded joint were investigated. Each factor had 2 levels (23 full factorial design). The statistical analysis result showed that the rolling pressure, rolling speed, rolling offset, interaction between rolling pressure and rolling speed, interaction between rolling speed and rolling offset were statistically significant factors, with the most compressive residual stress value approximately -391.6 MPa. The appropriated deep rolling process parameters on surface residual stress of AA7075-T651 aluminum alloy friction stir welded joint were 1) rolling pressure about 150 bar 2) rolling speed about 1,400 mm/min 3) rolling offset about 0.1 mm.

Influence of Turn-Rolling on the Residual Stresses and Microstructure of C45E and the Effects on Fatigue Life under Cyclic Loading

2021 ◽  
Vol 76 (3) ◽  
pp. 195-204
Author(s):  
B. Denkena ◽  
P. Kuhlemann ◽  
B. Breidenstein ◽  
M. Keitel ◽  
N. Vogel
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
Service Life ◽  
Rolling Process ◽  
Deep Rolling ◽  
Edge Zone ◽  
Residual Stress State ◽  
Machining Speed ◽  
Component Service Life ◽  
Positive Effect

Abstract The microstructure and the residual stress state have a significant influence on the service life of the component. The deep rolling process already enables a significant increase in the strength and service life of highly stressed components. By using the hybrid manufacturing process of turn rolling, the edge zone properties can be influenced to such an extent that the service life is further increased compared to conventional deep rolling. In addition to a change in the residual stress state, the use of the turning process temperature also leads to a significant grain refinement in the edge zone area, which has a positive effect on the component service life. This modification of the edge zone can be significantly influenced by the machining speed.

scholarly journals Effects of ultrasonic surface rolling process on tribological behavior of 4Cr13 stainless steel

2022 ◽  
Author(s):  
Xiaoshuang Luo ◽  
Shengpeng Zhan ◽  
Dan Jia ◽  
Jiesong Tu ◽  
Yinhua Li ◽  
...  
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Stainless Steel ◽  
Sample Surface ◽  
Rolling Process ◽  
Near Surface ◽  
Maximum Value ◽  
Sample Height ◽  
Suitable Treatment ◽  
Strengthening Technique

Abstract Ultrasonic surface rolling (USR) process is a novel surface strengthening technique based on the tool head's high-frequency impact on the workpiece. USR can cause severe plastic deformation on the superficial surface of metal material, and greatly improving the mechanical properties of the material. This paper elucidates the effects of USR passes on the surface roughness, sample height, microstructure, microhardness, residual stress, and tribological properties of 4Cr13 stainless steel. The results revealed that multiple USR treatments refined the near-surface layer grain of the sample. Compared with untreated sample, USR treatments significantly improved the surface roughness and microhardness of the samples. Obvious compressive residual stress and plastic deformed with a maximum value of about -723 MPa and a depth of about 229 μm were also introduced into the sample surface. Under a dry friction environment, the samples that underwent the USR treatments exhibited significantly enhanced wear resistance, and six rolling passes were found to be the most suitable treatment.

Investigation of residual stress distribution induced during deep rolling of Ti-6Al-4V alloy

2020 ◽  
Vol 235 (1-2) ◽  
pp. 186-197
Author(s):  
Kunpeng Han ◽  
Dinghua Zhang ◽  
Changfeng Yao ◽  
Liang Tan ◽  
Zheng Zhou ◽  
...  
Keyword(s):  
Residual Stress ◽  
Compressive Residual Stress ◽  
Three Dimensional ◽  
Longitudinal Direction ◽  
Circumferential Direction ◽  
Two Dimensional ◽  
Deep Rolling ◽  
Three Dimensional Model ◽  
Surface Residual Stress ◽  
Near Surface

To clarify the effects of deep rolling parameters on residual stress, two-dimensional and three-dimensional finite element models were developed using the Chaboche hardening model. Both two-dimensional and three-dimensional simulation results were compared with experimental results. The three-dimensional model is more accurate, especially the 90° cut-out model. The maximum errors in the longitudinal and circumferential directions of 90° cut-out are 8.9% and 15.6%, respectively. Compared to 20 MPa, a rolling pressure of 38 MPa results in larger and deeper compressive residual stress in both directions, but lower surface residual stress in the circumferential direction. Compared to 30% overlap, 60% overlap produces larger compressive residual stress in the near surface region in the longitudinal direction and deeper residual stress with lower maximum compressive residual stress in the circumferential direction. The friction coefficient only slightly affects residual stress in the circumferential direction; increasing the rolling speed induces higher near surface residual stress in the circumferential direction. Compared to the HG6 tool, the HG8 tool generates decreasing surface residual stresses and deeper residual stress in both directions. Compared to one pass, two passes significantly increase the residual stress in circumferential direction, but only slightly increase the residual stress in the longitudinal direction.

Numerical Investigation on Heat Transfer and Residual Stress in a Butt Welded Plate

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
D. Kumaresan ◽  
A. K. Asraff ◽  
R. Muthukumar
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Thermal History ◽  
Plastic Material ◽  
Welding Process ◽  
Welding Residual Stress ◽  
Source Distribution ◽  
Geometrical Shape ◽  
Element Analysis ◽  
Alloy Plate

It is a well known fact that during welding, the metal at the welding zone gets melted and then solidifies, which results in shrinkage in all directions. Residual strain and stress distributions coming from shrinking are largely influenced by the nature and configuration of the welding process, metallurgical characteristics of weld, and the geometrical shape of the weld joint. The residual stress mainly depends on the thermal history cycle through which the specimen undergoes in the welding process. So these thermal history cycles are to be known in order to get a better knowledge of the welding phenomenon and to minimize the risk of failures. In this work, a detailed analysis has been carried out for predicting the heat flow pattern and stress distribution in an aluminum alloy plate during welding. In this study, the modified double ellipsoidal heat source distribution pattern is modeled and considered for the weld pool design. Elastic-plastic material properties at various temperatures are also considered for simulation. A detailed finite element analysis is carried out to predict the welding residual stress. In this, thermal analysis is carried out for actual variable welding speed and these transient thermal histories at various locations were numerically predicted and compared with experimental results. Further, these thermal results are used to predict the residual stress on the weld plate using finite element method.

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