Integrating effect of forming in fatigue life prediction: review of present scenario and challenges
22 Feb 2012-Vol. 226, Iss: 6, pp 967-979
TL;DR: In this article, the residual stresses of sheet metal deformation during forming induces complex residual stresses in the component owing to its geometry and material anisotropy, which affect the durability of the component.
Abstract: Plastic deformation of sheet metals during forming induces complex residual stresses in the component owing to its geometry and material anisotropy. The residual stresses affect the durability of t...
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TL;DR: In this article, the incremental hole drilling (IHD) technique is tested to measure residual stresses, being able to reach a 2-mm measuring depth, and a commercial strain gage is used and calibrated using finite element model simulations.
Abstract: Ball-burnishing induces compressive residual stresses on treated materials by the effect of plastic deformation. The result is an increase in the fatigue life of the treated part, retarding the initiation of cracks on the surface. Compressive residual stresses have been previously measured by X-ray diffraction near the surface, revealing considerably high values at the maximum analyzed depth, in relation to other finishing processes such as shot peening. However, the maximum analyzed depth is very limited by using this technique. In this paper, the incremental hole drilling (IHD) technique is tested to measure residual stresses, being able to reach a 2-mm measuring depth. To that objective, a commercial strain gage is used and calibrated using finite element model simulations. A second Finite Element Model based on material removal rate is developed to obtain the equations to calculate the strain release through IHD. Finally, residual stresses are measured experimentally with that technique on two...
35 citations
Cites background from "Integrating effect of forming in fa..."
...) [7], and a longer lifespan of industrial components can be expected, as explained by Hariharan and Prakash [8]....
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...[7], and a longer lifespan of industrial components can be expected, as explained by Hariharan and Prakash [8]....
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TL;DR: In this article, a robust multiobjective optimization based on evolutionary algorithm is proposed to minimize the error in yield stress and plastic strain ratio simultaneously and thereby overcomes the limitations in the approaches used before.
Abstract: The texture induced anisotropy of yield strength in cold rolled sheet metals is modeled using anisotropic yield criteria. The classical and other optimization methods used so far to determine the yield coefficients are limited by fixed set of experimental data, initial guess values, and pre-determined weight factors. A robust multiobjective optimization based on evolutionary algorithm proposed in this paper minimizes the error in yield stress and plastic strain ratio simultaneously and thereby overcomes the limitations in the approaches used before. The new approach is tested using Hill48 and Barlat89 yield criteria for five different materials from literature. The new approach is observed to improve the prediction capability of yield coefficients when compared to earlier approaches. The Pareto frontier obtained in the new approach can serve as a comparative tool to evaluate the accuracy of different yield criteria.
19 citations
Cites background from "Integrating effect of forming in fa..."
...The complex mechanical behavior of different materials [5] and the demand for accurate modeling of forming process [2, 6, 7] have led to the development of several advanced yield functions [1, 8– 10]....
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...Assuming orthotropic symmetry, several phenomenological models have been proposed in the past to describe the anisotropy of yield strength [1, 2]....
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01 Jan 2001
17 citations
TL;DR: In this paper, the authors assess tensile and high cycle fatigue performance of dual-phase (DP590) steel subjected to uniaxial and equi-biaxial pre-strain.
15 citations
References
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TL;DR: In this article, a plane stress yield function for orthotropic sheet metals called "Yld2003" is proposed, which contains eight anisotropy parameters which can be fitted to selected experimental input data.
90 citations
TL;DR: In this paper, room-temperature total strain-controlled low-cycle fatigue tests were carried out on AISI 304LN austenitic stainless steel specimens that were cold worked by swaging to different levels (10, 20 and 30% reduction in area) prior to testing.
81 citations
"Integrating effect of forming in fa..." refers background in this paper
...The longitudinal cracking commonly observed in austenetic stainless steel components is owing to the detrimental effect of residual stresses induced by the martensitic transformation during the forming process.(36,50) This indicates that the material being formed and the process parameters play an important role on the residual stress distribution in a sheet metal component....
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TL;DR: In this paper, a wavelet bump extraction (WBE) algorithm is used to extract fatigue damaging events or bumps in the record that cause the majority of the fatigue damage, whilst preserving the load cycle sequences.
76 citations
TL;DR: In this article, a polar coordinate representation of the yield surface in principal stress space is used to formulate constitutive equations for plane-stress plasticity of orthotropic sheets, and conditions for internal consistency of the model are derived.
74 citations
TL;DR: In this article, the effect of Manganese sulfides (MnS) on anisotropy of forged steel components is quantified using push-pull fatigue testing in longitudinal and short transversal directions.
Abstract: Anisotropy of forged steel components is especially adverse when it concerns rotationally symmetric components. Manganese sulfides (MnS) in steels may be desired for their improvement of machining properties; however, they also deteriorate fatigue behavior. A quantification of the effect of MnS on anisotropy is necessary to find an optimum for component dimensioning. To isolate the influence of MnS on anisotropy only, high cleanness of the test material is required. The test material in the current investigation was molten in a vacuum furnace to high-cleanness composition. Materials with two different S levels were produced to detect variations in anisotropy according to amount, shape, and distribution of the MnS inclusions. The two batches were cross-rolled to plates with a deformation ratio of 4.5. The MnS phase constitutes, upon forging or rolling, pancake-shaped inclusions. In the case of cross-rolling, an in-plane rotational symmetry of the inclusions could be created. The shape and size of these inclusions are essential for the mechanical behavior of the material. Push-pull fatigue testing was performed in longitudinal (in plane) and short transversal directions relative to the rolling plane. The results showed strong anisotropy of the fatigue behavior with inferior performance in short transverse directions where the principal stress is perpendicular to the flattened inclusions. The anisotropy was somewhat more pronounced for the high-S material, resulting from a different fatigue crack growth mechanism.
71 citations
"Integrating effect of forming in fa..." refers background in this paper
...The deformable sulphur inclusions (MnS) in steel can induce anisotropic effects in hot rolled steel, which in turn results in poor fatigue properties along transverse directions.(59,60) Most of the work discussed above and other similar work concentrated primarily on the experimental investigation of anisotropy effect....
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