Simulation Study of Cutting-Induced Residual Stress
11 Jun 2019-pp 341-350
TL;DR: In this paper, the effect of residual stresses on the service properties of machined parts is investigated using the finite element analysis (FEA) method for studying the surface layer deformation appeared from inherited residual stresses.
Abstract: The use of the finite element analysis (FEA) is an effective method for studying the surface layer deformation appeared from inherited residual stresses. This paper is devoted to the analysis of the effect of residual stresses to the service properties of parts and the development of a cutting-induced residual stresses simulation using the DEFORM software. The influence of residual stresses on the operational properties of machined parts is investigated. The fatigue strength of the product, which is provided as the result of forming in the cutting process of the surface layer structure, residual stresses and deformations, is used as a criterion for the decision-making about optimal structure and parameters of the functionally-oriented technological process. The causes of the occurrence of machine-induced residual stresses for different workpiece materials have been analyzed. The simulation model of residual machining-induced stresses is described. The functional dependence of the stress-strain state reflects the interference pattern of the frictional, force loads and the variable process of the deep thermal effects. It is proved, that the compression part of this cycle is determined by external load, and tensile—by residual stresses.
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10 Sep 2019
TL;DR: In this paper, the results of simulation of power, temperature and stress-strain parameters are the basis for developing predictive models of influence of the structure and parameters of the functional-oriented technological process on the formation of the wear parameters and corrosion resistance of the machined product.
Abstract: The methodological principles for the functional-oriented technological process planning are presented in the article. The introduction of a comprehensive system for ensuring the engineering product’s life cycle requires taking into consideration the operating conditions of the most loaded parts in the product not only at the design engineering stage, but also at the stage of the technology planning. Computer Aided Forming (CAF) system that implements the relationship between the technology of forming products with the conditions of their potential exploitation should be added to the integrated CAD/CAE/CAPP/CAM system. The results of simulation of power, temperature and stress-strain parameters are the basis for developing predictive models of influence of the structure and parameters of the functional-oriented technological process on the formation of the wear parameters and corrosion resistance of the machined product. It is proved that the residual stresses reflect the interference pattern of the fluctuation tensile (frictional and thermal) and compressive (force) loads, the dynamic picture of the deep thermal effects of the formation process and the peculiarities of the structural-phase transformations. It is shown, that the specific value of the strain component of roughness increases as a result of increased cutting speed and reduction of feed, which contributes to the formation of the surface microrelief with significant values of the reduced valley depth. This reduces the concentration of oxide products on the functional surface, resulting in increased product’s corrosion resistance.
10 citations
08 Sep 2020
TL;DR: In this paper, the results of rheological simulation of titanium alloys cutting processes using the DEFORM software are given, where the authors show that the machinability of the Titanium alloys essentially depends on the cutting parameters.
Abstract: Titanium alloys are difficult to machining due to their physical and mechanical properties. An effective method of research the cutting process is to study using simulation models. The article describes the results of rheological simulation of titanium alloys cutting processes using the DEFORM software. The results of the stress-strain and thermodynamic state of the workpiece and tool, cutting force studies in the chip formation zone depend on the machining parameters are given. It has been proven that the process of chip formation in the machining of titanium and nickel alloys takes place under conditions of unstable cutting, which contributes to the generation of residual stresses, which arise synchronously with the increase of radial cutting force. The result of this process is an intense tool wear and dynamic instability in the cutting zone. The machinability of the titanium alloys essentially depends on the cutting parameters. The main causes of low workability are high cutting temperature, saw-tooth type of chip (as a result of an asynchronous change in longitudinal and transverse cutting forces), the adiabatic process of the chip formation, tool vibration and intense tool wear.
4 citations
08 Sep 2020
TL;DR: The analysis of the antifriction material brass L63 surface layer formation mechanics during finishing Antifriction Non-abrasive Treatment (FANT) at the stage of micro-cutting was performed experimentally by the method of microhardness measurement and computer simulation using the finite element method (FEM).
Abstract: The analysis of the antifriction material brass L63 surface layer formation mechanics during finishing antifriction non-abrasive treatment (FANT) at the stage of micro-cutting was performed experimentally by the method of microhardness measurement and computer simulation using the finite element method (FEM) The analysis of the micro-cutting processes simulation results during FANT using the FEM allowed us to identify the main technologically important patterns It was found that large tensile stresses arise behind the contact surface in the surface layer of the brass tool, which leads to the formation of surface microcracks to facilitate micro-cutting during subsequent passages of the FANT On the back surface of the contact zone, there are extreme contact pressures for brass, which create the conditions for the formation of an adhesive durable brass antifriction layer The thickness of the deformation-hardened surface layer is very small and does not significantly affect subsequent technological transitions during coating
3 citations
10 Sep 2019
TL;DR: The optimal cutting modes and parameters according to the criterion of ensuring the required stability of the tool machine during the hobbing can be appointed.
Abstract: The results of a comprehensive study of the hobbing process dynamic parameters based on interrelated models are given in the article. The elastic cutting system is the first component of this system. Parameters of the elastic system are determined based on the simulation of the thickness and sectional area of the cutting cross-sections and by the analysis of the transient process of forming the cutting force in the system Deform 3D. The second component of the model includes the description of oscillating processes in the circuits of the hob and the workpiece of the toothed wheel. The method of experimental determination of the dynamic parameters of this system and the determination of its amplitude-phase frequency response is described. The equivalent elastic system and the own frequencies of the most powerful oscillations of the machine elements are analyzed. The behavior of the closed system of the machine with the cutting process under the influence of changing the cutting parameters (feed and cutting speed) is simulated in the Simulink MATLAB system. On the basis of this, the optimal cutting modes and parameters according to the criterion of ensuring the required stability of the tool machine during the hobbing can be appointed.
3 citations
01 Jan 2022
References
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TL;DR: A finite element analysis based on the nonlinear finite element code MSC is developed for investigating the effect of cutting speed and feed rate on surface and subsurface residual stresses induced after orthogonal cutting.
80 citations
TL;DR: In this paper, a finite element-based model of orthogonal cutting was developed using DEFORM-2D and a full factorial cutting experiment was conducted using sharp tools to investigate the effect of feed rate and cutting speed on residual stresses under finish-turning conditions.
31 citations
TL;DR: In this paper, an analysis approach for the change in residual stress distribution is established according to the diffusion theory of cavity, which is also used to investigate cracks with different orientations.
Abstract: Many manufacturing processes can induce residual stresses in produced components. These residual stresses influence the mean stress during cyclic loading. The initial residual stresses induced during manufacturing change during fatigue damage. This paper presents a research on the change of residual stress distribution during fatigue crack propagation; the research predicts crack propagation by considering residual stress. An analysis approach for the change in residual stress distribution is established according to the diffusion theory of cavity, which is also used to investigate cracks with different orientations. Experiments are conducted to verify the prediction results of residual stress. A probability density function based on Weibull distribution is established to evaluate the accuracy of predicted residual stress. The influence of residual stress on fatigue crack propagation is considered the effective stress intensity factor range, which is calculated under the combined stress field of applied stress and residual stress. An analysis model of crack propagation is established. Furthermore, the model of crack propagation is used to estimate the velocity of crack propagation for the cases, same as the cases of residual stress prediction. The case studies show that the results are basically identical with the experimental results, indicating that the proposed approach is acceptable.
25 citations
SIDI1
TL;DR: In this paper, the effect of residual stress on the fatigue crack initiation was investigated for cyclic tension based on elasto-plastic analysis at notch, fatigue initiation lives were predicted using fatigue code.
Abstract: In this paper the effect of compressive residuals stresses generated by plastic preload on fatigue crack initiation and performed on 6061 Al-alloy finite plate with central hole was studied. Finite element analysis (FEA) was used to generate residual stress field. The effect of residual stress on the fatigue crack initiation was investigated for cyclic tension. Based on elasto-plastic analysis at notch, fatigue initiation lives were predicted using fatigue code. Results shown that the fatigue initiation lives were affected by the presence of compressive residual stress at notch and total residual field. Intuitionally, stress ratio effect in presence of residual stress was highlight.
9 citations