Modelling of Part Distortion Due to Residual Stresses Relaxation: An aerOnautical Case Study

D’Alvise, L.; Chantzis, Dimitrios; Schoinochoritis, Babis; Salonitis, Konstantinos

doi:10.1016/j.procir.2015.03.069

Cited by 42 publications

(12 citation statements)

References 10 publications

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“…Recent FEM advancements for machining distortion include: simplifying distortion to a bending moment, which is a function of the residual stress profile [6 -8]; using element "birth and death" to simulate material removal and deformations [9]; modeling residual stresses used in milling experiments using relaxation techniques [10]; and modeling quenched material to simulate machining deformations related to materials processing [11].…”

Section: Machining Distortionmentioning

confidence: 99%

Molecular dynamics simulations of single grain pure aluminum in a vice fixture for nanomanufacturing applications

Garcia

Zhang

Linke

et al. 2018

CIRP Journal of Manufacturing Science and Technology

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Although nano and macro manufacturing encompass two different scales of machining, investigating both is essential for understanding machining distortions and deformations. In both macro and nano fabrication, the fixture is the primary means of securing the workpiece in place while performing the manufacturing operations. Understanding the fixture design is a critical aspect relating the two different scales of manufacturing. This paper describes a method involving atomistic simulation for understanding machining distortions for the macro scale by investigation of nano machining and work holding devices. 2 This research aims to help bridge the knowledge gap in manufacturing of macro and nano scale applications. The simulations performed showed that the fixture influences the machining distortions and the critical stress concentrations on the workpiece.

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Section: Machining Distortionmentioning

confidence: 99%

Molecular dynamics simulations of single grain pure aluminum in a vice fixture for nanomanufacturing applications

Garcia

Zhang

Linke

et al. 2018

CIRP Journal of Manufacturing Science and Technology

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“…However, as AM processes can lead to various types of defects [15], [16], the quality of the manufactured parts is of major research interest. The research focus has been on optimizing the process parameters for manufacturing AM parts (as an example D'Alvise et al has focused in the part distortion due to residual stresses and how this could be optimized through modelling [17], [18]), with few studies on the lattice structures. Yan et al [9] investigated the dimensional accuracy and the mechanical properties of AlSi10Mg lattice structures fabricated via direct metal laser sintering (DMLS).…”

Section: Additive Manufacturing Of Lattice Componentsmentioning

confidence: 99%

A hybrid finite element analysis and evolutionary computation method for the design of lightweight lattice components with optimized strut diameter

Salonitis

Chantzis²,

Kappatos

2016

Int J Adv Manuf Technol

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Components incorporating lattice structures have become very popular lately due to their lightweight nature and the flexibility that additive manufacturing offers with respect to their fabrication. However, design optimization of lattice components has been addressed so far either with empirical approaches or with the use of topology optimization methodologies. An optimization approach utilizing multipurpose optimization algorithms has not been yet proposed. This paper presents a novel user-friendly method for the design optimization of lattice components towards weight minimization, which combines finite element analysis and evolutionary computation. The proposed method utilizes the cell homogenization technique in order to reduce the computational cost of the finite element analysis and a genetic algorithm in order to search for the most lightweight lattice configuration. A bracket consisting of both solid and lattice regions is used as a case study in order to demonstrate the validity and effectiveness of the method, with the results showing that its weight is reduced by 13.5% when using lattice structures. A discussion about the efficiency and the implications of the proposed approach is presented.

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“…To predict part distortions, models based on the finite element method have been proposed in the literature. 11–18 Finite element (FE) models aim to reduce part rework and scrap costs through the minimization of its distortions. In this sense, Dreier et al.…”

Section: Introductionmentioning

confidence: 99%

“…To model the residual stress distribution, the linear tetrahedron element (one integration point) is preferred, in most applications, 11–15 due to its capability to better adapt to complex geometries and the low computational cost necessary to perform the simulations. However, when high residual stress gradients are considered through the thickness of rolled plates and thin-walled workpieces, a FE model with a large number of tetrahedral elements is required to predict part distortions accurately.…”

Section: Introductionmentioning

confidence: 99%

On the convergence of solid meshes for the prediction of part distortions due to residual stresses

Albino

Beal

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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Residual stresses in rolled plates, used as raw material for the fabrication of aircraft components, arise from manufacturing processes such as rolling, casting, quenching, stretching, and thermal treatments. After each process, the rolled plate has a geometrically stable condition but with internal stresses. However, during part machining an unbalance in the distribution of residual stresses occurs, in special for aircraft components, due to the large amount of material removal throughout the process. This condition of instability leads to component distortions so that any corrective action affects the manufacturing lead-time and production costs. Part distortions are usually predicted by finite element analyses with linear tetrahedral meshes in which the residual stress profiles are applied as a constant value element-wise. In this work, both linear and quadratic solid meshes are employed to address this problem. For this purpose, a Python-based routine is implemented to apply the residual stress profile at the integration points of the elements. Then, finite element simulations of simple geometric configurations (plates and beams) under theoretical and real residual stress distributions are carried out. Performance and effectiveness of two different meshes—tetrahedral and hexahedral (brick-type)—are checked through comparison with results presented by classical plate and beam theories. A general good correlation for the deflections predicted by them is reached.

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Modelling of Part Distortion Due to Residual Stresses Relaxation: An aerOnautical Case Study

Cited by 42 publications

References 10 publications

Molecular dynamics simulations of single grain pure aluminum in a vice fixture for nanomanufacturing applications

Molecular dynamics simulations of single grain pure aluminum in a vice fixture for nanomanufacturing applications

A hybrid finite element analysis and evolutionary computation method for the design of lightweight lattice components with optimized strut diameter

On the convergence of solid meshes for the prediction of part distortions due to residual stresses

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