scholarly journals Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5092
Author(s):  
Usama Umer ◽  
Hossam Kishawy ◽  
Mustufa Haider Abidi ◽  
Syed Hammad Mian ◽  
Khaja Moiduddin
Keyword(s):  
Finite Element ◽  
Cutting Tool ◽  
Hardened Steel ◽  
Heat Transfer Analysis ◽  
Fe Model ◽  
Rotary Tool ◽  
Chip Flow ◽  
Heat Partitioning ◽  
Rotary Cutting ◽  
Good Agreement

This paper presents a model for assessing the performance of self-propelled rotary tool during the processing of hardened steel. A finite element (FE) model has been proposed in this analysis to study the hard turning of AISI 51200 hardened steel using a self-propelled rotary cutting tool. The model is developed by utilizing the explicit coupled temperature displacement analysis in the presence of realistic boundary conditions. This model does not take into account any assumptions regarding the heat partitioning and the tool-workpiece contact area. The model can predict the cutting forces, chip flow, induced stresses, and the generated temperature on the cutting tool and the workpiece. The nodal temperatures and heat flux data from the chip formation analysis are used to achieve steady-state temperatures on the cutting tool in the heat transfer analysis. The model outcomes are compared with reported experimental data and a good agreement has been found.

scholarly journals A finite element model of the electrofusion welding of thermoplastic pipes

1997 ◽  
Vol 211 (2) ◽  
pp. 137-146 ◽  
Author(s):  
G F Rosala ◽  
A J Day ◽  
A S Wood
Keyword(s):  
Finite Element ◽  
Thermal Deformation ◽  
Element Model ◽  
Time Dependent ◽  
Heat Transfer Analysis ◽  
Deformation Analysis ◽  
Fe Model ◽  
Closure Time ◽  
Gap Closure ◽  
Good Agreement

An advanced finite element (FE) model of the electrofusion welding of thermoplastic pipes has been developed using the ABAQUS FE package. The heat transfer analysis is coupled with thermal deformation analysis to include the time-dependent closure of the initial gap between the pipe and fitting. The effect of radial melt movement into the interface is modelled using a new ‘virtual material movement’ technique. The predicted results (temperature distribution in the weld region, melt affected zones and gap closure time) are compared with experimental data and good agreement is found.

Simulation and Optimization of Wedge-Shaped Ultrasonic Transducers Using Finite Element Method (FEM)

2013 ◽  
Vol 281 ◽  
pp. 112-115 ◽  
Author(s):  
Dan Jin ◽  
Zhao Hui Li
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Boundary Effect ◽  
Ultrasonic Transducers ◽  
Fe Model ◽  
Limited Size ◽  
Simulation And Optimization ◽  
Ultrasonic Flaw ◽  
Shape And Size ◽  
Good Agreement

Wedge-shaped transducers have been widely used in industry as probes for ultrasonic flowmeters or for ultrasonic flaw detectors. But by now, few studies have focused on the influence to the performance of the wedge-shaped transducers brought by their limited size. In this paper, the effect of the shape and size of wedge-shaped substrates on the whole transducer system is discussed and the shape and size of a transducer (0.5MHz) is optimized to eliminate the influence of the boundary effect by using a 2-D Finite Element (FE) model. Lastly, wedge-shaped transducers have been manufactured for experiment which shows a good agreement with the simulation.

Residual Stress Prediction for Non-Axisymmetric Vessel Penetration Welds

2008 ◽  
Author(s):  
Kazuo Ogawa ◽  
Nobuyoshi Yanagida ◽  
Koichi Saito
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Three Dimensional ◽  
Measurement Data ◽  
Fe Model ◽  
Stress Distributions ◽  
Dimensional Finite Element ◽  
Stress Prediction ◽  
Three Dimensional Finite Element ◽  
Good Agreement

Residual stress distribution in an oblique nozzle jointed to a vessel with J-groove welds was analyzed using a three-dimensional finite element method. All welding passes were considered in a 180-degree finite element (FE) model with symmetry. Temperature and stress were modeled for simultaneous bead laying. To determine residual stress distributions at the welds experimentally, a mock-up specimen was manufactured. The analytical results show good agreement with the experimental measurement data, indicating that FE modeling is valid.

An assessment of the Sachs method for measuring residual stresses in cold worked fastener holes

1998 ◽  
Vol 33 (4) ◽  
pp. 263-274 ◽  
Author(s):  
D J Smith ◽  
C G C Poussard ◽  
M J Pavier
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Cold Working ◽  
Element Model ◽  
Fe Model ◽  
Working Process ◽  
Element Analysis ◽  
Near Surface ◽  
Cold Worked ◽  
Good Agreement

Measurements of residual stresses in 6 mm thick aluminium alloy 2024 plates containing 4 per cent cold worked fastener are made using the Sachs method. The measurements are made on discs extracted from the plates. The measured tangential residual stress distribution adjacent to the hole edge are found to be affected by the disc diameter. The measured residual stresses are also in good agreement with averaged through-thickness predictions of residual stresses from an axisymmetric finite element (FE) model of the cold working process. A finite element analysis is also conducted to simulate disc extraction and then the Sachs method. The measured FE residual stresses from the Sachs simulation are found to be in good agreement with the averaged through-thickness predicted residual stresses. The Sachs simulation was not able to reproduce the detailed near-surface residual stresses found from the finite element model of the cold working process.

Overpressure Fragility Evaluation of a Mark I Drywell Using Thermal-Mechanical Finite Element Analysis

2014 ◽  
Author(s):  
Mohamed M. Talaat ◽  
David K. Nakaki ◽  
Kyle S. Douglas ◽  
Philip S. Hashimoto ◽  
Yahya Y. Bayraktarli
Keyword(s):  
Finite Element ◽  
Stress Analysis ◽  
Fe Analysis ◽  
Heat Transfer Analysis ◽  
Fe Model ◽  
Head Region ◽  
Element Analysis ◽  
Differential Movement ◽  
Steady State Heat ◽  
Steady State Heat Transfer

The overpressure fragility of a Mark I boiling water reactor drywell was performed by detailed finite element (FE) analysis. The drywell overpressure capacity is controlled by the onset of leakage in the bolted head flange connection once separation exceeds the capacity of the silicone rubber O-ring seals. The FE analysis was conducted at 6 discrete accident temperatures, ranging from 150 to 425°C. The overpressure evaluation used an axisymmetric model of the drywell head region for computational efficiency, and verified it by comparing to results from one FE model which used 3D solid elements. The mechanical properties of the steel materials were defined as temperature-dependent linear-elastic. The median overpressure capacity at each temperature was determined using a 2-step thermal-stress analysis procedure. First, a steady-state heat transfer analysis was conducted to map out the temperature distribution in the drywell wall, which is exposed to the accident temperature on the inside and ambient temperature on the outside. Second, a quasi-static multi-step stress analysis was performed. The vertical differential movement between the flange surfaces was monitored and compared to the O-ring rebound capacity to define the pressure at the onset of leakage. After leakage occurred, the relationship between leakage area and increased pressure was recorded. The evaluation predicted the median overpressure capacity and the lognormal standard deviation for uncertainty in O-ring rebound capacities, bolt preload, and model sophistication, in addition to the median pressure-leak area relationship.

Finite Element Modeling of Burr Formation in Orthogonal Metal Cutting

2008 ◽  
Vol 53-54 ◽  
pp. 71-76 ◽  
Author(s):  
Wen Jun Deng ◽  
C. Li ◽  
Wei Xia ◽  
X.Z. Wei
Keyword(s):  
Finite Element ◽  
Steady State ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Element Model ◽  
Burr Formation ◽  
Cutting Condition ◽  
Simulation Procedure ◽  
Chip Flow ◽  
Orthogonal Metal Cutting

A coupled thermo-mechanical model of plane-strain orthogonal metal cutting including burr formation is presented using the commercial finite element code. A simulation procedure based on Normalized Cockroft-Latham damage criterion is proposed for the purpose of better understanding the burr formation mechanism and obtaining a quantitative analysis of burrs at exit. The cutting process is simulated from the transient initial chip formation state to the steady-state of cutting, and then to tool exit transient chip flow, by incrementally advancing the cutting tool. The effects of cutting condition on the non-steady-state chip flow while tool exit can be investigated using the developed finite element model.

Multi-Phase FE Model for Machining Inconel 718

2010 ◽  
Author(s):  
Yu Long ◽  
Changsheng Guo ◽  
Santosh Ranganath ◽  
Ronald A. Talarico
Keyword(s):  
Finite Element ◽  
Titanium Carbide ◽  
Process Parameters ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Fe Model ◽  
Carbide Phases ◽  
Edge Geometry ◽  
Multi Phase ◽  
Machined Surfaces

Inconel 718 presents significant challenges in machining attributable to the secondary hard niobium and titanium carbide phases. Machined surfaces typically show a tendency of those brittle carbides to crack, drag and smear under the cutting tool. This paper presents a finite element modeling approach to predict the carbide cracking and distortion phenomenon. The influence of cutting process parameters and cutting edge geometry on carbide damages will be investigated with the model. The model results will be qualitatively compared with SEM observations of the machined surfaces.

Compressive Behavior of AA6061 at Room Temperature and Validation of the FE Model Based on Optical 3D Measurement Technique

2013 ◽  
Vol 594-595 ◽  
pp. 909-913
Author(s):  
A.B. Abdullah ◽  
Z. Samad
Keyword(s):  
Finite Element ◽  
Measurement Technique ◽  
Room Temperature ◽  
Element Model ◽  
Surface Measurement ◽  
Fe Model ◽  
Cold Upsetting ◽  
Element Simulation ◽  
The Finite Element Model ◽  
Good Agreement

Recently, manufacturing process simulation using finite element (FE) model become important. Therefore, validation of the finite element model is crucial. This study will present validation of 2D finite element simulation of cold heading at room temperature. Validation of the simulation model is carried out by comparing the resulted bulge profile of the cold upsetting specimen to the profile of the specimen, which is obtained from an optical 3D surface measurement technique namely Infinite Focus Alicona system. Based on the result, both profiles show a very good agreement.

Investigation on the Effect of Pulsating Pressure on Tube-Hydroforming Process

2011 ◽  
Vol 473 ◽  
pp. 618-623
Author(s):  
Khalil Khalili ◽  
Seyed Yousef Ahmadi-Brooghani ◽  
Amir Ashrafi
Keyword(s):  
Finite Element ◽  
Internal Pressure ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Element Model ◽  
Fe Model ◽  
Axial Feeding ◽  
Hydroforming Process ◽  
The Finite Element Model ◽  
Good Agreement

Tube hydroforming process is one of the metal forming processes which uses internal pressure and axial feeding simultaneously to form a tube into the die cavity shape. This process has some advantages such as weight reduction, more strength and better integration of produced parts. In this study, T-shape tube hydroforming was analyzed by experimental and finite element methods. In Experimental method the pulsating pressure technique without counterpunch was used; so that the internal pressure was increased up to a maximum, the axial feeding was then stopped. Consequently, the pressure decreased to a minimum. The sequence was repeated until the part formed to its final shape. The finite element model was also established to compare the experimental results with the FE model. It is shown that the pulsating pressure improves the process in terms of maximum protrusion height obtained. Counterpunch was eliminated as being unnecessary. The results of simulation including thickness distribution and protrusion height were compared to the part produced experimentally. The result of modeling is in good agreement with the experiment. The paper describes the methodology and gives the results of both experiment and modeling.

On torsional stiffness and natural frequency of bellows

2004 ◽  
Vol 218 (3) ◽  
pp. 263-271 ◽  
Author(s):  
C L Lu ◽  
T X Wu ◽  
J G Yu ◽  
Q T Ye
Keyword(s):  
Finite Element ◽  
Natural Frequencies ◽  
Integration Method ◽  
Torsional Stiffness ◽  
Fe Model ◽  
Expansion Joint ◽  
Pipe Model ◽  
Thin Walled Pipe ◽  
Thin Walled ◽  
Good Agreement

Simplified formulae for torsional natural frequencies of bellows are developed using an equivalent thin-walled pipe model. To do this the torsional stiffness of bellows needs to be worked out. The torsional stiffness of bellows is determined using Chien's integration method. Accordingly, the Expansion Joint Manufactures Association (EJMA) formula for torsional stiffness calculation is modified using two different equivalent radii. The torsional natural frequencies of bellows are calculated using the simplified formulae based on the equivalent thin-walled pipe model and the modified formulae for torsional stiffness of bellows. The results from the simplified formuale are verified by those from a finite element (FE) model and good agreement is shown between the simplified formulae and the FE model.

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