scholarly journals Application of DIC Method in the Analysis of Stress Concentration and Plastic Zone Development Problems

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3460 ◽  
Author(s):  
Paweł J. Romanowicz ◽  
Bogdan Szybiński ◽  
Mateusz Wygoda
Keyword(s):  
Heat Treatment ◽  
Stress Concentration ◽  
High Strength Steels ◽  
High Strength ◽  
Experimental Tests ◽  
Theoretical Models ◽  
Material Behavior ◽  
Image Correlation ◽  
Stress Concentrations ◽  
Element Analysis

The paper presents the assessment of the possibility and reliability of the digital image correlation (DIC) system for engineering and scientific purposes. The studies were performed with the use of samples made of the three different materials—mild S235JR + N steel, microalloyed fine-grain S355MC steel, and high strength 41Cr4 steel subjected to different heat-treatment. The DIC studies were focused on determinations of dangerous zones with large stress concentrations, plastic deformation growth, and prediction of the failure zone. Experimental tests were carried out for samples with different notches (circular, square, and triangular openings). With the use of the DIC system and microstructure analyses, the influence of different factors (laser cutting, heat treatment, material type, notch shape, and manufacturing quality) on the material behavior were studied. For all studied cases, the stress concentration factors (SCF) were estimated with the use of the analytical formulation and the finite element analysis. It was observed that the theoretical models for calculations of the influence of the typical notches may result in not proper values of SCFs. Finally, the selected results of the total strain distributions were compared with FEM results, and good agreement was observed. All these allow the authors to conclude that the application of DIC with a common digital camera can be effectively applied for the analysis of the evolution of plastic zones and the damage detection for mild high-strength steels, as well as those normalized and quenched and tempered at higher temperatures.

Testing and Modeling of Roll Levelling Process

2014 ◽  
Vol 611-612 ◽  
pp. 1753-1762 ◽  
Author(s):  
Elena Silvestre ◽  
Eneko Sáenz de Argandoña ◽  
Lander Galdos ◽  
Joseba Mendiguren
Keyword(s):  
Finite Element ◽  
High Strength Steels ◽  
Beam Theory ◽  
High Strength ◽  
Theoretical Models ◽  
Element Model ◽  
Forming Process ◽  
Element Analysis ◽  
Design Engineers ◽  
Ultra High Strength Steels

Roll levelling is a forming process used to remove the residual stresses and imperfections of metal strips by means of plastic deformations. During the process the metal fibres are subjected to cyclic tension-compression deformations leading to achieve flat product. The process is especially important to avoid final geometrical errors when coils are cold formed or when thick plates are cut by laser. In the last years, and due to the appearance of high strength materials such as Ultra High Strength Steels, machine design engineers are demanding a reliable tool for the dimensioning of the levelling facilities. In response to this demand, Finite Element Analysis and Analytical methods are becoming an important technique able to lead engineers towards facilities optimization through a deeper understanding of the process. Aiming to this study two different models have been developed to analyze the roll levelling operations: an analytical model and a finite element model. The FE-analysis was done using 2D-modelling assuming plane strain conditions. Differing settings, leveller configuration and materials were investigated. The one-dimensional analytical levelling model is based on classical beam theory to calculate the induced strain distribution through the strip, and hence the evolving elastic/plastic stress distribution. Both models provide a useful guide to process-sensitivities and are able to identify causes of poor leveller performance. The theoretical models have been verified by a levelling experimental prototype with 13 rolls at laboratory.

Study of Sheared Edge Formability of Ultra-High Strength DP980 Sheet Metal Blanks

2019 ◽  
Vol 141 (9) ◽  
Author(s):  
Saeid Nasheralahkami ◽  
Weitian Zhou ◽  
Sergey Golovashchenko
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Strength Steels ◽  
High Strength ◽  
Material Behavior ◽  
Element Analysis ◽  
Advanced High Strength Steels ◽  
Sheared Edge ◽  
Ultra High Strength Steels ◽  
Lower Tool

Advanced high strength steels (AHSS) and ultra-high strength steels (UHSS) have been increasingly implemented by the automotive industry for better crashworthiness and fuel economy. However, these steels are often sensitive to the trimmed edge cracking. The objective of the present paper is to study the sheared edge of ultra-high strength dual-phase steel, DP980, in mechanical trimming and hole punching by sheared edge quality assessment, stretchability, and hole expansion tests as well as finite element analysis. Furthermore, the mechanism of fracture propagation in trimming and hole punching processes of DP980 was discussed. Rather a unique fracture mechanism was observed for trimming of DP980 steel leading to the burr removal at the final stage of the trimming process. Finite element analysis revealed that, under very large clearances, a secondary crack initiates from the edge of the lower tool, and the primary propagated crack turns toward it simultaneously. Intersecting of these two cracks leads to the total separation and leaves the edge of the trimmed part with a broken burr. Fracture observation of trimmed specimens revealed that crack initiation sites under tension moved from the middle of the trimmed surface toward the burr tip with increasing the clearance. This study demonstrates the importance of stretchability tests for designing the stamping dies as well as a reliable finite element simulation for characterizing the material behavior during the shearing process.

scholarly journals Tribological Behavior of Laser Textured Hot Stamping Dies

2016 ◽  
Vol 2016 ◽  
pp. 1-15 ◽  
Author(s):  
Andre Shihomatsu ◽  
Sergio Tonini Button ◽  
Iris Bento da Silva
Keyword(s):  
Surface Topography ◽  
High Pressures ◽  
Hot Stamping ◽  
High Strength Steels ◽  
High Strength ◽  
Experimental Tests ◽  
Textured Surface ◽  
Laser Texturing ◽  
Stamping Dies ◽  
Before And After

Hot stamping of high strength steels has been continuously developed in the automotive industry to improve mechanical properties and surface quality of stamped components. One of the main challenges faced by researchers and technicians is to improve stamping dies lifetime by reducing the wear caused by high pressures and temperatures present during the process. This paper analyzes the laser texturing of hot stamping dies and discusses how different surfaces textures influence the lubrication and wear mechanisms. To this purpose, experimental tests and numerical simulation were carried out to define the die region to be texturized and to characterize the textured surface topography before and after hot stamping tests with a 3D surface profilometer and scanning electron microscopy. Results showed that laser texturing influences the lubrication at the interface die-hot sheet and improves die lifetime. In this work, the best texture presented dimples with the highest diameter, depth, and spacing, with the surface topography and dimples morphology practically preserved after the hot stamping tests.

scholarly journals Experimental Investigation on the Effect of Shot Peening and Deep Rolling on the Fatigue Response of High Strength Fasteners

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1093 ◽  
Author(s):  
Reggiani
Keyword(s):  
Fatigue Life ◽  
Shot Peening ◽  
High Strength Steels ◽  
High Strength ◽  
Experimental Tests ◽  
Published Data ◽  
Deep Rolling ◽  
Beneficial Impact ◽  
The Impact ◽  
Fatigue Life Enhancement

Shot-peening and deep rolling are mechanical surface treatments that are commonly applied to enhance the fatigue performances of components, owing to their capacity to generate compressive residual stresses and induce work hardening. However, literature is still poor of published data concerning the application of these treatments to high strength steels fasteners, although these represent a class of components among the most widespread. In the present work, the impact of deep rolling and shot-peening performed in the underhead radius of two set of fasteners made of 36NiCrMo and 42CrMoV for fatigue life enhancement has been investigated. The experimental tests consisted of six combinations of shot-peening and deep rolling, including the non-treated state. Two test campaigns have been sequentially carried out with different process parameters and treatment sequences. The results always showed a beneficial impact of the deep rolling on fatigue, especially for the 42CrMoV steel. Conversely, the effect of the shot-peening strongly depended on the selected set of parameters, alternatively leading to an improvement or a worsening of the fatigue life in relation to the level of induced surface roughness.

Laser Assisted Cold Bending of High Strength Steels

2014 ◽  
Author(s):  
Erica Liverani ◽  
Alessandro Ascari ◽  
Alessandro Fortunato ◽  
Adrian Lutey
Keyword(s):  
Heat Treatment ◽  
High Strength Steels ◽  
High Strength ◽  
Processing Parameters ◽  
Cold Forming ◽  
Steel Sheets ◽  
Phase Lead ◽  
Cold Bending ◽  
Bending Process ◽  
Definition Of

This paper presents the feasibility of an innovative application of laser-assisted bending process. The high strength steel sheets bending, carried out after a laser heat treatment, is studied. Several strategies aimed at obtaining a ductile structure along the bending line, suitable for cold forming, are investigated. The influence of laser processing parameters on the microstructure, hardness and strength of the sheets are discussed and analyzed. In order to predict the temperature and ensure the repeatability and reliability of the process, a model for heat treatment simulation is developed. The study of the experimental data and the integration with the simulation of the heating phase lead to the definition of specific process parameters suitable for achieving a crack-free cold bending of high strength steels.

Characterization of Heat Transfer Coefficients of Tool Materials and Tool Coatings for Hot Stamping of Boron-Manganese Steels

2010 ◽  
Vol 438 ◽  
pp. 81-88 ◽  
Author(s):  
Michael Wieland ◽  
Marion Merklein
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Hot Stamping ◽  
High Strength Steels ◽  
High Strength ◽  
Tool Steels ◽  
Transfer Coefficients ◽  
Element Analysis ◽  
Coated Tool

One characteristic of hot stamping of ultra high strength steels is the high wear rate of the used tools which leads to shorter tool life. Coatings improving wear resistance can increase the lifetime of the used tools but process relevant data such as the heat transfer capability of coated tool steels are missing. Within this paper the heat transfer capabilities of coated tool steels for the hot stamping processes are determined. Therefore different coating systems based on AlCrN are applied on the tool steels and the pressure dependent heat transfer coefficient is determined using process relevant conditions. As semi-finished blank the hot stamping steel 22MnB5 with an aluminum-silicon pre-coating is used. With respect to a finite element analysis of the forming operation of the hot stamping process the heat transfer coefficient represents an important input data for the process layout.

Finite Element Analysis of a Locked Bolt With an Initial Crack

2009 ◽  
Author(s):  
Jean Paul Kabche ◽  
Mauri´cio Rangel Pacheco ◽  
Ivan Thesi ◽  
Luiz Carlos Largura
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Operating Conditions ◽  
Material Behavior ◽  
Isotropic Hardening ◽  
Stress Concentrations ◽  
Engineering Structures ◽  
Element Analysis ◽  
Micro Cracks ◽  
Non Linear

Bolted connections are largely employed in various types of engineering structures to transfer loads from one member to another. In particular, the off-shore industry has made extensive use of these connections, predominantly at the sub-sea level. In spite of their advantages, bolted joints are critical regions and may become sources of structural weakness due to large stress concentrations. Under severe operating conditions, micro-cracks can develop in the bolt, creating regions of elevated stress which may significantly reduce the integrity of the connection and ultimately lead to failure. This paper presents the three-dimensional finite element analysis of a steel locked bolt assembly aimed to assess the effect of micro-cracks on the structural integrity of the assembly using the commercial finite element package ANSYS. Non-linear contact between the bolt and nut threads is considered, where frictional sliding between components is allowed. A bi-linear isotropic hardening model is used to account for non-linear material behavior. The assembly is loaded by applying a pre-load of fifty percent of the yield stress of the material, according to the API-6A Norm. Two geometric models are investigated: a healthy locked bolt assembly with no initial cracks; and a damaged model, where a circular crack is introduced at the root of the bolt threads. The effect of the crack size is studied by modeling the crack with three different radius sizes. The J-Integral fracture mechanics methodology was used to study the stress concentrations in the damaged model.

Finite Element Stress Analysis of Composite Sucker Rods

2003 ◽  
Vol 125 (4) ◽  
pp. 299-303 ◽  
Author(s):  
Eyassu Woldesenbet
Keyword(s):  
Finite Element ◽  
High Stress ◽  
Experimental Tests ◽  
Fatigue Loading ◽  
Stress Concentrations ◽  
Element Analysis ◽  
Composite Rod ◽  
Rod System ◽  
Sucker Rod ◽  
2D And 3D

Analysis of polymer-matrix composite sucker rod systems using finite element methods is performed. Composite sucker rods used in oil production fail mainly due to fatigue loading. In majority of cases, the failure is in the region of the joint where the composite rod and the steel endfitting meet. 2D and 3D Finite Element Analysis and experimental tests are carried out in order to observe the stress distribution and to find the regions of stress concentrations inside the endfitting. The causes of failure of the composite sucker rods are identified as high transverse compressive stress caused by overloading that results in the crushing of the rod, and high stress concentrations present at the grooves of the endfitting that initiate premature cracks. Based on the result of this study, enhanced design of the composite sucker rod system can be accomplished.

Experimental Analysis of Self-Folding SMA-Based Sheet Design for Simulation Validation

2014 ◽  
Author(s):  
Aaron C. Powledge ◽  
Darren J. Hartl ◽  
Richard J. Malak
Keyword(s):  
Performance Metrics ◽  
Permanent Deformation ◽  
Material Behavior ◽  
Image Correlation ◽  
Design Parameters ◽  
Radius Of Curvature ◽  
Element Analysis ◽  
Performance Metric ◽  
3D Digital Image Correlation ◽  
Thermally Actuated

The goal of this research is to experimentally characterize the capabilities of a concept for a self-folding reconfigurable sheet for use in origami-inspired engineering design and to use this characterization to validate simulations of physics-based models of the sheet. The sheet consists of an active, self-morphing laminate that contains two shape memory alloy (SMA) mesh layers and a passive compliant medium between these layers. The SMA layers are thermally actuated, allowing bending to occur in both positive and negative directions to create soft hill and valley folds. These folds are completely reversible, allowing the structure to fold and unfold without permanent deformation. Unlike past work on self-folding structures, these sheets can have folds along any line, be subsequently unfolded, and then be folded again in a new way. To explore the effect of changing design parameters on the performance metrics of the sheet, it is desirable to use Finite Element Analysis (FEA) simulations instead of relying on time consuming experiments. Such models have been created incorporating user material subroutines (UMATs) in an FEA solver such as Abaqus to capture material behavior, but these must now be validated against experimental data to establish how well they match experimental performance. The primary performance metric of the sheet was chosen to be the radius of curvature measured perpendicularly to the line of heating. Both experiment and simulation focus on the radius of curvature achieved by the sheet for a given set of design parameters and actuation path. The goal of validation is to achieve a desirable level of agreement and repeatability in these results. To measure the deformation and curvature in the sheet as it actuates, a 3D Digital Image Correlation (3D DIC) system is employed to track the movement of points along the surface of the sample as it is heated to a temperature above the transformation temperature of the SMA and allowed to fully actuate. These tools are utilized for a number of samples so that validation of the sheet encompasses multiple values for each of the primary design parameters.

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