An analytical method for continuously predicting mechanics and residual stress in fillet surface turning

Weng, Jian; Liu, Yang; Zhuang, Kejia; Xu, Dongdong; M’Saoubi, Rachid; Hrechuk, Andrii; Zhou, Jinming

doi:10.1016/j.jmapro.2021.07.004

Cited by 13 publications

(7 citation statements)

References 40 publications

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“…Furthermore, considering all studied cases, the inaccuracy of σ ij w.r.t. to the FE results was found to become smaller for larger h, as expected according to better fulfillment of Equation (12). However, these inaccuracies seem somewhat less sensitive w.r.t.…”

Section: Js Methodssupporting

confidence: 67%

“…The condition on the residual strain ε r ξξ will only be guaranteed for the MM approach but not for the method of JS; compare Equations (11) and (12). Furthermore, since the JS approach enforces σ ξξ = σ * ξξ , the corresponding residual stress component will generally not be approximated well but vanish after a complete pass below the loaded region.…”

Section: Approximate Plane-strain Rolling and Sliding Contact Algorithmsmentioning

confidence: 99%

“…To treat both methods and their respective conditions, Equations ( 11) and (12), in a unified formalism, we now adopt the notation proposed by McDowell [8], so that the MM and JS schemes may be recovered by setting Ψ = 0 or Ψ = 1, respectively, in the derivations to follow. Then, the conditions εξξ = 0 (MM, Ψ = 0) and σξξ = σ * ξξ (JS, Ψ = 1) can be summarized to the single equation εξξ…”

Section: Approximate Plane-strain Rolling and Sliding Contact Algorithmsmentioning

confidence: 99%

“…Ulutan et al [9] and Liang and Su [10] later published similar applications using the algorithms of Jiang and Sehitoglu [7] and McDowell [8], respectively, while applying analytic cutting force models to estimate the surface loads' magnitudes. Since then, a multitude of methodologically rather similar studies have been carried out for various manufacturing processes such as turning [11,12], milling [13][14][15], or additive manufacturing [16,17], which differ w.r.t. the surface load modeling but all rely on the same mechanical baseline assumptions and the algorithms of Jiang and Sehitoglu [7] or McDowell [8] to attempt estimating residual stresses depth profiles.…”

Section: Introductionmentioning

confidence: 99%

“…For this purpose, the two simple FE models shown in Figure 5 were established. They each consist of a single plane-strain finite element with boundary conditions, nodal forces, surface tractions and temperature prescribed specifically so as to impose the kinematic constraints and the elastic stress components defined by Equations ( 11) and (12). By appropriate definition of the temporal evolution of these loads, we can simulate the thermoelastoplastic behavior of a single material point for arbitrary loading histories under the exact mechanical assumptions of MM and JS using the constitutive models included in Abaqus.…”

mentioning

confidence: 99%

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On the Applicability of Approximate Rolling and Sliding Contact Algorithms in Anisothermal Problems with Thermal Softening

2022

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The residual stress approximation methods formulated by McDowell and Moyar, Jiang and Sehitoglu, and McDowell for rolling and sliding contact problems are reconsidered in the context of single anisothermal loading cycles and isotropic hardening. A consistent extention to incorporate thermal softening is developed and the generalized thermoelastoplastic algorithms are cast into a proper predictor–corrector formulation. Detailed explicit and implicit numerical integration strategies are presented and validated using specifically designed finite element models that conform to the underlying mechanical assumptions. Then, the applicability of the approximate algorithms to anisothermal problems with isotropic hardening and thermal softening is analyzed by assuming a rate-independent Johnson–Cook-type yield stress model and by comparing the obtained transient and residual stresses to results from full-scale finite element half-space models under varying loading and strain-hardening intensities. An in-depth, comparative discussion on the adequacy of the algorithms in conjunction with the justification of their respective mechanical simplifications follows. Sufficiently strong strain hardening is found to be a prerequisite for accurate predictions, and Jiang and Sehitoglu’s approach is deemed to be preferable for the considered type of problem. The conclusions drawn from the investigations are discussed in the context of common applications with particular emphasis on manufacturing process modeling and the corresponding guidelines are proposed for such use cases.

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Section: Js Methodssupporting

confidence: 67%

Section: Approximate Plane-strain Rolling and Sliding Contact Algorithmsmentioning

confidence: 99%

Section: Approximate Plane-strain Rolling and Sliding Contact Algorithmsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

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On the Applicability of Approximate Rolling and Sliding Contact Algorithms in Anisothermal Problems with Thermal Softening

2022

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Multi-axis ball-end milling force prediction model considering the influence of cutting edge

Zhuang

Yan

Dai

et al. 2023

Int J Adv Manuf Technol

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Numerical and experimental investigations on residual stress evolution of multiple sequential cuts in turning

Weng,

Zhou,

Zhang

et al. 2023

Int J Adv Manuf Technol

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Residual stress is of great importance on the fatigue life of components, nevertheless, most of the simulations of turning operation focus on the rst cut and ignore the evolution of residual stress in sequential cutting. The present study aims to explore the surface residual stress pro le along the feed direction during longitudinal turning, to understand the impact of sequential cuts on turning-induced residual stress. A Coupled Eulerian-Lagrangian (CEL)-based three-dimensional (3D) numerical model is employed to stably predict the evolution of residual stress of multiple sequential cuts in turning integrated with complete material removal process of each cut. The effectiveness and accuracy of the proposed model are veri ed though the good agreement between simulated and measured results. The results show that the surface residual stress gradually decreases with increasing cutting sequence under the condition of different tool nose radius and feed rates. It is also found that the main reason of this phenomenon is the initial stress state generated by the former tool path. For a single case, the drop of tensile residual stress from the rst cut to the third cut can be more signi cant when a larger feed rate is employed.

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An analytical method for continuously predicting mechanics and residual stress in fillet surface turning

Cited by 13 publications

References 40 publications

On the Applicability of Approximate Rolling and Sliding Contact Algorithms in Anisothermal Problems with Thermal Softening

On the Applicability of Approximate Rolling and Sliding Contact Algorithms in Anisothermal Problems with Thermal Softening

Multi-axis ball-end milling force prediction model considering the influence of cutting edge

Numerical and experimental investigations on residual stress evolution of multiple sequential cuts in turning

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