Surface roughness characterization for fatigue life predictions using finite element analysis

Ås, Sigmund Kyrre; Skallerud, Bjørn; Tveiten, Bård Wathne

doi:10.1016/j.ijfatigue.2008.05.020

Cited by 108 publications

(37 citation statements)

References 17 publications

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“…The fact that parameters S a and S ku are almost insensitive to the value of the lead angle tends to confirm that the arithmetical parameters are not adapted to describe the microgeometry of machined and its influence on fatigue [3].…”

Section: Surface Roughness Measurementsmentioning

confidence: 99%

“…This is particularly true for milling of high strength steels with ball-end tools that are used to machine complex shape parts. Indeed, most studies dedicated to the influence of machining on fatigue were carried out on turning [1][2][3][4] and the rare studies published on milling are dealing with aluminium alloys [5].…”

Section: Introductionmentioning

confidence: 99%

“…However, the role of micro-geometry on the fatigue life becomes essential in the absence of residual stresses or when their amplitude is small [8]; this is generally the case for aluminium alloys but also for steels subjected to a finishing operation with a depth of cut lower than 0.5 mm. Hence, most published studies [2][3][4][5]8,9] on the effect of surface integrity on the fatigue life focus on the effect of the micro-geometry of the machined surface. Subsequently, the effect of surface integrity on the endurance limit is then linked to the stress concentration near the multiple notches that are induced by the machining process, as taken account for instance by the model proposed by Arola and Ramulu [9,10].…”

Section: Introductionmentioning

confidence: 99%

“…These soft or hard inclusions may affect the mechanical properties, leading to various mechanisms of micro-crack initiation -in the subsurface or in the bulk of the material [3], in the matrix or at the inclusions [11]-so that the endurance limit decreases even for a macroscopic homogeneous uniaxial stress state.…”

Section: Introductionmentioning

confidence: 99%

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Prediction of the endurance limit taking account of the microgeometry after finishing milling

Guillemot

Lartigue

Billardon

et al. 2010

Int J Interact Des Manuf

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The aim of this study is to investigate the influence on the high cycle fatigue behaviour of high strength steels of the surface micro-geometry induced by their machining. The machining process considered herein is high speed finishing milling with a ball-end tool. The micro-geometry of the machined surface is characterized by 2-and 3-D roughness parameters. The studied material is a 25MnCrSiVB6 resulphurized steel with a bainitic matrix. The high cycle fatigue behaviour of this material is characterised by its endurance limit evaluated from symmetric tension-compression (R σ = −1) tests performed according to standard staircase method. This endurance limit was compared to the results of so-called self-heating tests as well as rupture tests performed according to Locati approach. It appears that the difference between the endurance limits measured on the machined or the polished specimens is not fully accounted for by the self-heating measurements. Furthermore, the Arola-Ramulu model also appears as being unable to predict the influence of the surface integrity induced by the milling process on the high cycle fatigue life of this material. Last, a sensitivity analysis of the lead angle of the tool on the anisotropy of the machined surface micro-geometry proves that the roughness of surfaces milled with ball-end tools must be characterized by surface-and not linear-parameters.

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Section: Surface Roughness Measurementsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Prediction of the endurance limit taking account of the microgeometry after finishing milling

Guillemot

Lartigue

Billardon

et al. 2010

Int J Interact Des Manuf

View full text Add to dashboard Cite

show abstract

“…This work was supported in part by the regional growth fund provided by UK Government (RGF Grant Award 01.09.07.01/1789C). [9] and As et al [10], both used Finite Element Analysis (FEA) of measured topologies of machined surfaces without cusps to calculate the stress concentration of aluminium alloy induced by surface roughness. The surfaces were measured using diamond stylus instrument and an optical surface profiler respectively.…”

Section: Introductionmentioning

confidence: 99%

Effect of Cusp Size, Depth and Direction on Stress Concentration

Tabriz¹,

Barrans²

2018

IJMMM

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Recently multi-axial machining technology has improved significantly. It has become a widely accepted method of manufacturing components with complex, free form surfaces. Solid billet materials with negligible internal defects are used in this process. This provides increased durability and fatigue life over equivalent cast components. However, multi-axial machining leaves cusps as machining marks. The combination of tool size and step-over generates cusps with different depths and widths. Even though the cusps add extra material on top of the nominal surface, the Finite Element Analysis simulations presented in this paper show that the maximum stress generated within the cusps can be greater than that predicted from the cusp-free geometry. These stress concentrations generated by cusps can reduce the fatigue life and durability of a machined component.In this paper a full factorial analysis of the effect of tool size, cusp width/step-over and cusp direction has been conducted. The analysis uses five different levels of tool size and cusps width and four levels of cusp direction. The results can be used to determine a tool size, cusp width and cusp direction combination with minimum spurious stress raising effect.Index Terms-Cusp depth, cusp direction, cusp size, finite element analysis, stress concentration.

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3D Multilevel Modeling of Surface Roughness Influences on Hole Expansion Ratios

Wechsuwanmanee

Lian

Münstermann

2021

steel research int.

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The steel grade DP1000 is widely used in various industrial application fields. Its mechanical properties satisfy basic requirements in terms of strength and global formability due to the tailored microstructure composed of ductile ferrite and hard martensite. Nevertheless, the edge crack sensitivity of dual‐phase steels is still of interest. For its evaluation, hole expansion tests have become a standard experimental approach. Finite element simulation is a tool that further supports the assessment of edge crack resistance by providing insights into local stress and strain fields at the formed edges during hole expansion tests. However, there are still discrepancies between the experiments and simulations in terms of force–displacement curves and hole expansion ratios due to several factors including the hole edge surface condition. To overcome these discrepancies, this work proposes a 3D multiscale simulation strategy to quantify this factor under a complex loading case and to include it into the simulation approaches. The workflow is sufficiently general to handle arbitrary load cases. Compared with state‐of‐the‐art ductile damage mechanics simulations, the accuracy of the simulations is significantly improved.

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Surface roughness characterization for fatigue life predictions using finite element analysis

Cited by 108 publications

References 17 publications

Prediction of the endurance limit taking account of the microgeometry after finishing milling

Prediction of the endurance limit taking account of the microgeometry after finishing milling

Effect of Cusp Size, Depth and Direction on Stress Concentration

3D Multilevel Modeling of Surface Roughness Influences on Hole Expansion Ratios

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