Three-dimensional mapping of the residual stress field in a locally rolled aluminium alloy specimen

Coules, Harry; Horne, Graeme; Kabra, Saurabh; Colegrove, Paul A.; Smith, David J.

doi:10.1016/j.jmapro.2017.02.010

Cited by 24 publications

(19 citation statements)

References 33 publications

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“…Therefore, the measurement and evaluation of residual stress across surface and sub-surface is crucial to validate the parametric model. Residual stress can be detrimental in terms of deteriorating surface properties instead of the expected burnishing effect if the process is not well controlled [16]. Depending on the burnishing force and track width (i.e., stepover), the net material flow affects the type (i.e., compressive or tensile) and amount of residual stress into the surface.…”

Section: Discussionmentioning

confidence: 99%

“…Further, while the importance of the experimental approach is paramount, computational technique is vital to develop the underlying insight and predict the characteristic of the process in a shorter period time, and in an effective manner. Previously, both 2D and 3D finite element (FE) modelling of ball/roller-burnishing of hard metals have been explored and validated experimentally [9,[16][17][18]. However, the process has not been employed towards the burnishing of relatively soft Mg alloys.…”

Section: Introductionmentioning

confidence: 99%

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Finite Element Analysis of Surface Integrity in Deep Ball-Burnishing of a Biodegradable AZ31B Mg Alloy

Uddin

Hall

Hooper

et al. 2018

Metals

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Abstract:As an effective and affordable technique, deep ball-burnishing has been applied to induce the plastic deformation of material, thus resulting in an increased surface hardness, compressive residual stress, and finish quality. Recent research shows that the fast degradation of an Mg alloy implant is a prime limiting factor for its success in in vivo human trials. This paper presents a comprehensive investigation into deep ball-burnishing of a biodegradable AZ31B Mg alloy, in order to improve the alloy's surface integrity. A series of experiments using an in-house built burnishing tool with a 10-mm steel ball have been conducted, with a key focus of exploring the influence of the major process parameters-e.g., burnishing force (750-2650 N), feed rate (150-500 mm/min), and step-over (0.05-0.15 mm)-on hardness and finish quality. With the aim of performing a parametric sensitivity study, a three-dimensional (3D) finite element (FE) model is developed to predict the deformation mechanics, plastic flow, hardness, and residual stress. The FE model agrees with the experiment, hence validating the reliability of the model. Results show that while burnishing significantly improves surface integrity compared to the untreated surface, burnishing force and step-over are shown to be dominant. The net material movement dictates generated residual stress (tensile or compressive), often negatively affecting the surface integrity (e.g., surface cracks), which may be responsible for the onset of corrosion. An appropriate burnishing strategy must therefore be planned, in order to achieve the intended process outcome. The resulting surface properties, enhanced by the deep ball-burnishing, are expected to potentially increase the corrosion resistance of AZ31B Mg alloy implants.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis of Surface Integrity in Deep Ball-Burnishing of a Biodegradable AZ31B Mg Alloy

Uddin

Hall

Hooper

et al. 2018

Metals

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“…As a consequence, a smooth and shiny surface with better fatigue strength is obtained [1]. The depth of the work-hardening layer depends on the process parameters and material, but in general, it is small and varies between 0.2-1 mm [9,18].…”

Section: Post-machining Distortion Mitigation Techniquesmentioning

confidence: 99%

Distortions in Large Aluminum Forgings: Current Situation and Simulation Challenges

Mena

Guinard

Aguado

et al. 2020

Computational Methods in Applied Sciences

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Distortions after machining of large aluminum forgings are a recurrent problem for the aeronautical industry. These deviations from design geometry are caused by the presence of residual stresses, which are developed along the manufacturing chain. To solve this problem, a series of post-machining operations called reshaping are required. Despite reshaping manages to restore the correct geometry, it is highly manual and time-consuming, therefore, there is a need at an industrial level to use numerical simulation to study reshaping. The present document describes the problem of distortion, the operations required to mitigate these geometrical defects and the challenges associated to simulate reshaping.

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“…Destruction measurement techniques have been used for many years because of high accuracy, but they can cause destruction to specimen. Therefore, destructive measurement techniques are not applicable to expensive or nondestructive specimens [19,20]. As a powerful method, numerical simulation with lower cost, high efficiency and flexibility characteristic is widely used for stress measurement and investigation; especially, with the development of the microelectronic industry, the microelectronic reliability is becoming more and more important and the failure of electronic device always is an issue concerning coupled physical field.…”

Section: Introductionmentioning

confidence: 99%

Optimal Design of Co/In/Cu Sputtering Target Assembly Using Finite Element Method and Taguchi Method

Jiang

Zhang

Liu

2019

Acta Metall. Sin. (Engl. Lett.)

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Target assembly is a key consumable material for producing thin film used in the electronic packaging and devices. The residual stresses induced during the process of soldering are detrimental to the performance of target assembly. In this work, the intensity and distribution of the soldering residual stress of Co/In/Cu target assembly subjected to a 20 W/(m 2 K) cooling condition corresponding to the actual air cooling process were studied, based on finite element simulation and Taguchi method, to optimize the sputtering target assembly. Effects of different control factors, including solder material, thickness of solder layer, target and backing plate, on the soldering residual stress of target assembly are investigated. The maximum residual stress is calculated as 9.28 MPa in the target located at 0.16 mm from target-solder layer interface and at a distance of 0.78 mm from symmetry axis. The optimal design in target assembly has the combination of indium solder material, cobalt target at 12 mm thick, solder layer at 0.8 mm thick, copper backing plate at 15 mm thick. Moreover, solder material is the most important factor among control factors in the target assembly.

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Three-dimensional mapping of the residual stress field in a locally rolled aluminium alloy specimen

Cited by 24 publications

References 33 publications

Finite Element Analysis of Surface Integrity in Deep Ball-Burnishing of a Biodegradable AZ31B Mg Alloy

Finite Element Analysis of Surface Integrity in Deep Ball-Burnishing of a Biodegradable AZ31B Mg Alloy

Distortions in Large Aluminum Forgings: Current Situation and Simulation Challenges

Optimal Design of Co/In/Cu Sputtering Target Assembly Using Finite Element Method and Taguchi Method

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