Towards real-time prediction of residual stresses induced by peripheral milling of Ti–6Al–4V

Wölfle, Christoph Hubertus; Wimmer, Matthias; Hameed, Muhammed Zubair Shahul; Krempaszky, Christian; Zäh, Michael F.; Werner, Ewald

doi:10.1007/s00161-020-00938-5

Cited by 5 publications

(5 citation statements)

References 28 publications

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“…However, as discussed in Section 4.1, much larger step sizes may be used with the implicit algorithm without compromising on accuracy, as is expected from an implicit integration method in a path-dependent problem. This proves useful in performance critical scenarios, as considered e.g., by Wölfle et al [4], in which the additional effort of a Newton iteration might thereby be balanced against the need to compute the thermoelastic input solution on a much finer discretization, which certainly comes at a cost, especially if double convolution integrals are evaluated numerically over the whole domain for each grid point as is commonly done [9,11,[13][14][15][16][17]23].…”

Section: Discussionmentioning

confidence: 99%

“…However, it seems that no integral-free, closed-form solution exists for the thermoelastic problem. Therefore, the elastic input solution σ * ij will be computed by the FEM as described in Section 3, although faster approximate methods [4] or even heuristic approaches [1] are favorable in applications.…”

Section: Analysis Of the Approximation Quality For Half-space Problemsmentioning

confidence: 99%

“…Nevertheless, more efficient approximate approaches are still of interest in special applications. As an extreme example, FE approaches are prohibitively expensive if real-time capability is desired e.g., for model-based manufacturing process control [4]. Given such circumstances, one might resort to simpler, semi-analytical modeling strategies.…”

Section: Introductionmentioning

confidence: 99%

“…In doing so, we cast the algorithms' treatment of elastoplastic increments into a proper predictor-corrector form and provide detailed implementation-ready numerical schemes for both explicit and implicit solutions of the corrector step. The implicit scheme is deemed particularly useful when the evaluation of the elastic input solution on very fine grids comes at a computational cost that is non-negligible to the application, e.g., when real-time predictions are needed [4]. In such cases, larger step sizes might be preferable over the additional effort introduced by an implicit integration method.…”

Section: Introductionmentioning

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: Discussionmentioning

confidence: 99%

Section: Analysis Of the Approximation Quality For Half-space Problemsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

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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“…Ti-6246 alloy is an alpha-beta titanium alloy offering very high mechanical strength with good retention up to 450 • C. The alloy is heat-treatable and deep-harden-able. Ti-6246 alloy is mainly used in the manufacture of compressor discs, blades and other parts of aero-engines [3][4][5]. Due to the inhomogeneous microstructure of the material, in the random distribution of material defects and the uncertainty in processing and manufacturing there is usually a certain dispersion in fatigue life for the same loading conditions.…”

Section: Introductionmentioning

confidence: 99%

Failure Rate Model of Materials under Uncertain Constant Amplitude Cyclic Load

Bai

Wei

et al. 2022

Metals

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Failure rate is an important reliability index of mechanical components. Failure rate is usually used to characterize the degradation rule of material performance under the cyclic load, which is critical to fatigue life prediction as well as reliability assessment of Ti–6Al–2Sn–4Zr–6Mo (Ti-6246) alloy. In order to reveal the probability characteristics of failure rate of Ti-6246 alloy under uncertain cyclic load, the equation of P-S-N curve is studied in this paper. Firstly. The probability density function for fatigue life under uncertain cyclic loading is derived from the probability density function for external stresses. A probabilistic model for the failure rate is then presented based on the basic assumptions. It is assumed that the failure rate and fatigue life of the material depend on the same damage state. Finally, the validity of the proposed model is verified by the Ti-6246 alloy fatigue test. The results show that the fatigue life of Ti-6246 alloy is more affected by material parameters (internal factors) than stress (external factors) under uncertain constant amplitude cyclic loading.

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Numerical prediction of machining-induced surface residual stress for TC4 cryogenic turning

Wang

Liu³

et al. 2021

Int J Adv Manuf Technol

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Towards real-time prediction of residual stresses induced by peripheral milling of Ti–6Al–4V

Cited by 5 publications

References 28 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

Failure Rate Model of Materials under Uncertain Constant Amplitude Cyclic Load

Numerical prediction of machining-induced surface residual stress for TC4 cryogenic turning

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