Numerical and experimental investigation on thermo-mechanically induced residual stress in high-speed milling of Ti-6Al-4V alloy

Ullah, Irfan; Zhang, Song; Waqar, Saad

doi:10.1016/j.jmapro.2022.02.039

Cited by 38 publications

(14 citation statements)

References 48 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The machining‐induced residual stress is another important indicator of surface integrity, which significantly influences the machined part's strength, service duration, and reliability 36,37 . Residual stress has different effects on the component life depending on whether they are tensile or compressive.…”

Section: Methodsmentioning

confidence: 99%

“…Residual stress has different effects on the component life depending on whether they are tensile or compressive. Generally, tensile residual stress, which is generated on the machined surface due to the low thermal conductivity of titanium alloys 38 and excessive temperature gradients on the machined surface, 36 is considered unfavorable for the component's service performance. Conversely, compressive residual stresses can significantly increase the service performance 39–42 .…”

Section: Methodsmentioning

confidence: 99%

See 1 more Smart Citation

Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

Song

Pei

et al. 2023

Fatigue Fract Eng Mat Struct

View full text Add to dashboard Cite

Conformal contact is a commonly presented contact form in assemblies. Nonproportional loading is the main characteristics of conformal contact, which leads to prominent difficulty in revealing fretting crack behavior. In this paper, a finite element prediction model for Ti-6Al-4V pin-hole contact fretting fatigue crack initiation was developed, which simultaneously considered the effect of fretting wear, surface roughness, surface skewness, surface kurtosis, and residual stress. The results show that phase differences of stress component, change in direction of principal stress, and high stress gradient are the main reasons for the initiation of fretting fatigue under conformal contact condition. The model based on the Fatemi-Socie (FS) parameter successfully predicted the location, orientation, and fatigue life of crack initiation, which agrees well with the experimental results. Additionally, machining-induced residual stress can effectively inhibit mode I crack initiation at valleys. Moreover, ignoring the surface microgeometry characteristics reduces the prediction accuracy of the crack behavior.

show abstract

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

Song

Pei

et al. 2023

Fatigue Fract Eng Mat Struct

View full text Add to dashboard Cite

show abstract

“…Zhao et al [22] analyzed the evolution law of the residual stress field in the process of casting, heat treatment and machining of diesel engine block through the finite element method, and proposed an evolutionary analysis method of the residual stress field of metal components. Ullah et al [24] proposed a numerical and experimental method for in-depth prediction of partial residual stress in milling Ti-6Al-4V alloy, and studied the influence of white layer on the residual stress of workpiece during milling. Zhao et al [25] established a random multi-shot finite element model for predicting the residual compressive stress distribution of high-strength steel considering the elastic-plasticity of the projectile, and studied the effects of process parameters, initial surface topography and initial residual stress on the residual stress distribution after shot peening.…”

Section: Introductionmentioning

confidence: 99%

A novel genetic-based residual stress and deformation prediction method for the coupled machining process of connecting rod

Zhou¹,

Peng

Li³

et al. 2023

Preprint

View full text Add to dashboard Cite

Residual stress is the main factor that causes the deformation of connecting rod during its coupled machining process. Thus, it is essential to predict the residual stress and deformation of the connecting rod before its machining. As the traditional independent analysis method is no longer suit to the coupled machining process, a novel genetic-based method is processed. Firstly, the genetic mechanism of residual stress field and deformation field was established to realize the effective correlation of multiple machining process simulation models. Secondly, a milling process was established based on the birth and death element method, which converts complex milling processes into dynamic loading of milling forces and the death of elements of the FEM model. It realizes the coupling of initial residual stress (IRS) and machining induced residual stress (MIRS). Then, a multi-process simulation model of heat treatment, cutting off, and milling of connecting rod is established, which can reveal the evolution law of residual stress field under multi-process coupling of connecting rod, the coupling mechanism between IRS and MIRS, and the deformation response law of big hole cylinder of connecting rod. The proposed method will have great significance to the deformation control of connecting rod.

show abstract

“…4 However, the characteristics of TATWC greatly increase the probability of chattering during machining, which has a great negative impact on the quality and processing cost of processed workpieces. 5,6 The appearance and application of UVA milling method provides a new technology to overcome the processing problems of the TATWC. 7 Accurate dynamic model is the basis for studying the stability of UVA.…”

Section: Introductionmentioning

confidence: 99%

Stability analysis of TATWC based on UVA milling method

Yuan

Wenfang

et al. 2023

Advances in Mechanical Engineering

View full text Add to dashboard Cite

Difficult machining characteristics of titanium alloy materials and low rigidity characteristics of thin-walled component make Titanium Alloy Thin-Walled Component (TATWC) prone to chatter during machining, resulting in poor surface quality and other defects, which restricts the expansion and application of TATWC in the special industrial field. The appearance of Ultrasonic Vibration Assisted (UVA) milling method provides a new technology to overcome the processing problems of the TATWC. To analyze the stability of the TATWC processed by UVA milling method, first, by introducing a characterization function, a cutting force model of UVA milling method is established; The coefficients of cutting force between milling cutters and TATWC are solved through experiments. The model is verified by comparing the experimental and predicted values of cutting force; Secondly, the stability prediction model of UVA milling method based on full discrete method is established, and the effect of various process parameters on the stability of UVA milling method is researched. Finally, based on theoretical analysis, the modal characteristics of TATWC are measured through modal experiments. The feasibility of the stability prediction model of UVA milling method is verified by cutting TATWC with variable cutting depth.

show abstract

Numerical and experimental investigation on thermo-mechanically induced residual stress in high-speed milling of Ti-6Al-4V alloy

Cited by 38 publications

References 48 publications

Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

A novel genetic-based residual stress and deformation prediction method for the coupled machining process of connecting rod

Stability analysis of TATWC based on UVA milling method

Contact Info

Product

Resources

About