Analytical and Experimental Approach of Residual Stress on Deep-Rolled Crankshafts and Auto-Fretted Diesel Injection Rails. Effect on Fatigue Resistances in Service

2011 ◽  
Vol 681 ◽  
pp. 261-266 ◽  
Author(s):  
H. Michaud ◽  
Jean Michel Sprauel
Keyword(s):  
Residual Stress ◽  
High Pressure ◽  
Residual Stresses ◽  
Analytical Model ◽  
Fatigue Damage ◽  
Fatigue Resistance ◽  
Experimental Approach ◽  
Industrial Process ◽  
Diesel Injection ◽  
Fatigue Criterion

The fatigue resistance of car components such as crankshafts or diesel injection rails is mainly related to fatigue at geometrical singularities. Its understanding requires the simulations of the different steps of the industrial process resulting in residual stresses generation and their evolutions in service. First concerning crankshaft fatigue damage, a complete analytical model of residual stresses generation and shakedown in fatigue is presented. Then a fatigue criterion is established and validated for this application. Finally, for the high pressure diesel injection rail, this approach can be generalized to the holes intersection singularities.

Modeling of residual stresses by correlating surface topography in machining of AISI 52100 steel

2021 ◽  
pp. 1-26
Author(s):  
Chao Liu ◽  
Yan He ◽  
Yufeng Li ◽  
Yulin Wang ◽  
Shilong Wang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cutting Force ◽  
Surface Topography ◽  
Analytical Model ◽  
Analytical Models ◽  
Workpiece Surface ◽  
Dynamic Cutting Force ◽  
Intermittent Cutting ◽  
Effect Of Surface

Abstract The residual stresses could affect the ability of components to bear loading conditions and also the performance. The researchers considered workpiece surface as a plane and ignored the effect of surface topography induced by the intermittent cutting process when modeling residual stresses. The aim of this research develops an analytical model to predict workpiece residual stresses during intermittent machining by correlating the effect of surface topography. The relative motions of tool and workpiece are analyzed for modeling thermal-mechanical and surface topography. The influence of dynamic cutting force and thermal on different positions of surface topography is also considered in analytical model. Then the residual stresses model with the surface topography effect can be developed in intermittent cutting. The analytical models of dynamic cutting force, surface topography and residual stresses are verified by the experiments. The variation trend of evaluated values of the residual stress of workpiece is basically consistent with that of measured values. The compressive residual stress of workpiece surface in highest point of the surface topography are higher than that in the lowest point.

scholarly journals Analytical and Experimental Study of Residual Stresses in Thermal Barrier Coatings Deposited on Gas Turbine Blades in Laboratory Dimensions by APS and HVOF Methods to Calculate the Optimal Thickness

2021 ◽  
Vol 3 (1) ◽  
pp. 63-67
Author(s):  
Esmaeil Poursaeidi ◽  
◽  
Farzam Montakhabi ◽  
Javad Rahimi ◽  
◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Analytical Model ◽  
Thermal Barrier Coatings ◽  
Gas Turbines ◽  
Turbine Blades ◽  
Thermal Barrier ◽  
Inlet Temperature ◽  
Optimal Thickness ◽  
Barrier Coatings

The constant need to use gas turbines has led to the need to increase turbines' inlet temperature. When the temperature reaches a level higher than the material's tolerance, phenomena such as creep, changes in mechanical properties, oxidation, and corrosion occur at high speeds, which affects the life of the metal material. Nowadays, operation at high temperatures is made possible by proceedings such as cooling and thermal insulation by thermal barrier coatings (TBCs). The method of applying thermal barrier coatings on the turbine blade creates residual stresses. In this study, residual stresses in thermal barrier coatings applied by APS and HVOF methods are compared by Tsui–Clyne analytical model and XRD test. The analytical model results are in good agreement with the experimental results (between 2 and 8% error), and the HVOF spray method creates less residual stress than APS. In the end, an optimal thickness for the coating is calculated to minimize residual stress at the interface between the bond coat and top coat layers.

Residual Stress and Stress Corrosion Cracking of High Pressure Hydrocarbon Transmission Pipelines

2006 ◽  
Author(s):  
Greg Van Boven ◽  
Ronald Rogge ◽  
Weixing Chen
Keyword(s):  
Residual Stress ◽  
High Pressure ◽  
Residual Stresses ◽  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Stress Gradient ◽  
Corrosion Cracking ◽  
Tensile Residual Stress ◽  
Surface Residual Stress ◽  
Residual Stress Gradient

Stress corrosion cracking (SCC) can occur on the exterior surface of high pressure hydrocarbon transmission pipelines fabricated from low carbon steels. Both the initiation of SCC and the ability of SCC to progressively increase in depth is a complex and poorly understood phenomena. Previous empirical evidence suggests that residual stresses may be involved in this initiation and growth process. This paper describes a laboratory research project designed to investigate the correlation between residual stress and SCC. In this project, tensile test specimens with increasing levels of compressive and tensile residual stress on the surface and through the thickness of the specimen were fabricated. These stresses were sufficiently large as to dominate the other slight variations in material properties that may occur on identically formed test specimens. The residual stresses were then mapped across the length and through the depth of the specimens by a non-destructive neutron diffraction technique. A SCC initiation process was applied to the specimens. It was found that the formation of micro-pitting, to a depth up to 200 μm, occurred preferentially in areas where tensile residual stresses were the highest (about 300 MPa). Initiation of SCC, although found all at the bottom of this micro-pitting, occurred with a 71% normalized frequency in locations where the surface residual stress was in the range of 150 MPa to 200 MPa. Experimental data revealed that cracks generated in near-neutral pH environments can be readily blunted, due to both plastic deformation (room temperature creep) and extensive dissolution. As a result, a high positive tensile residual stress gradient is necessary for developing cracks in pipeline steels exposed to near-neutral pH environments. The tensile residual stress represents a large mechanical driving force for initial crack nucleation and short crack growth. Active cracks may become dormant as the near-surface residual stress gradient changes from a high to a low tensile stress or if the stress becomes compressive due to self-equilibration through the wall thickness direction. Special conditions may exist in pipeline steels where crack dormancy may not occur within a short distance to the surface, which may include, for example, the presence of a large tensile residual stress gradient over a longer distance, particular microstructures conducive to galvanic corrosion, and special environmental conditions susceptible to hydrogen-induced cracking.

Analysis and Prediction of Residual Stresses in Nitrided Tool Steel

2011 ◽  
Vol 681 ◽  
pp. 352-357 ◽  
Author(s):  
Bojan Podgornik ◽  
Vojteh Leskovšek ◽  
Miha Kovačič ◽  
Joze Vižintin
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Fatigue Resistance ◽  
Tool Steel ◽  
Plasma Nitriding ◽  
Near Surface ◽  
Stress Evaluation ◽  
Nitriding Time ◽  
Precise Knowledge ◽  
Steel Increase

Plasma nitriding is a thermo-chemical process of high importance for engineering components, which through generation of near-surface compressive residual stresses significantly improves wear and fatigue resistance. A precise knowledge of the level and distribution of residual stresses that exist in surface engineered components is necessary for accurate prediction of a component’s fatigue resistance. However, measurement of residual stress is not always possible, especially in the case of industrial tools and dies. Therefore, other methods for residual stress evaluation and prediction are required by industry. Results of this investigation show that residual stress level and depth in plasma nitrided tool steel increase by nitriding time and temperature. On the other hand, experimental data show that residual steel distribution in plasma nitrided tool steels can be determined on the basis of microhardness depth distribution.

Retained Austenite and Residual Stress Evolution in Carbonitrided Shot-Peened Steel

2011 ◽  
Vol 681 ◽  
pp. 374-380 ◽  
Author(s):  
S. Van Wijk ◽  
Manuel François ◽  
E. Sura ◽  
M. Frabolot
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Shot Peening ◽  
Industrial Process ◽  
High Hardness ◽  
Residual Austenite ◽  
Stress Evolution ◽  
X Ray Diffraction ◽  
Austenite Transformation ◽  
Compressive Residual Stresses

Carbonitriding followed by shot peening is an important industrial process to improve the mechanical properties of components, especially by producing compressive residual stresses. In addition, a high hardness and strength produced by this process enhances the surface properties and leads also a high resistance to fatigue. In this study, shot peening with different parameters have been employed to treat the carbonitrided specimens. The measurements of residual stress and residual austenite were performed by X-ray diffraction. It is shown, with a simple eigenstrain model, that residual austenite transformation under shot impact contributes to a significant fraction of residual stresses. When the material (750 HV) is peened with 800 HV shot, it represents about 50%, the remaining is due to plasticity. When it is peened with 640HV shot, 100% of residual stresses can be explained by austenite transformation.

Residual Stress in High-Pressure Water Jet Assisted Turning of Austenitic Stainless Steel

2006 ◽  
Vol 524-525 ◽  
pp. 581-586 ◽  
Author(s):  
Malek Habak ◽  
Jean Lu Lebrun ◽  
Stefan Waldmann ◽  
Patrick Robert ◽  
Cyril Fischer
Keyword(s):  
Residual Stress ◽  
High Pressure ◽  
Stainless Steel ◽  
Residual Stresses ◽  
Water Jet ◽  
Dry Turning ◽  
Chip Shape ◽  
Surface Residual Stresses ◽  
Pressure Water ◽  
High Pressure Water Jet

In this paper, the effect of a high pressure water jet, directed into the tool chip interface, on surface residual stresses and chip shape, in face turning of AISI 316L stainless steel has been investigated. Tests have been carried out with a standard cutting tool. This tool is not specifically meant for the machining of this type of material. The cutting speeds used were 80 m/min and 150 m/min, with a constant feed rate of 0.1 mm/rev and a constant cutting depth of 0.1 mm. Three jet pressures were used: 20, 50 and 80 MPa. Residual stress profiles have been analysed using the X-ray diffraction method in both longitudinal and transversal directions. The results show that by using a high pressure jet directed into the tool-chip interface, it is possible to create a well fragmented chip in contrast to the continuous chip formed using dry turning. It is also possible to control the chip shape and increase tool life. When the jet pressure is increased the residual stress at the surface decreases however it is increased by an increase in cutting speed. It can be concluded that surface residual stresses can be reduced by the introduction of a high pressure water jet. A reduction in the residual stress value by about 20 to 40 % can be observed when using high pressure water jet assisted turning compared to dry turning. Also, it has been observed that the jet pressure does not have a great influence on the depth affected by residual stress and by hardening.

scholarly journals High Pressure Interpass Rolling of Wire + Arc Additively Manufactured Titanium Components

2014 ◽  
Vol 996 ◽  
pp. 694-700 ◽  
Author(s):  
Paul A. Colegrove ◽  
Filomeno Martina ◽  
Matthew J. Roy ◽  
Blanka A. Szost ◽  
Sofiane Terzi ◽  
...  
Keyword(s):  
Residual Stress ◽  
High Pressure ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Contour Method

Wire + Arc Additively Manufactured components contain significant residual stresses that manifest in distortion. Each layer of an additively manufactured wall was rolled with the aim of reducing the residual stress. Neutron diffraction and contour method measurements show that the residual stresses were reduced particularly at the boundary with the substrate. The process also reduced distortion, and refined the microstructure which may facilitate implementation on aerospace components.

Residual Stress in Railway Rails by IP/cosα Method

2006 ◽  
Vol 524-525 ◽  
pp. 381-386 ◽  
Author(s):  
Toshihiko Sasaki ◽  
Shunichi Takahashi ◽  
Kengo Iwfuchi ◽  
Yukio Satoh ◽  
Yoshikazu Kanematsu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Fatigue Damage ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
X Ray Diffraction ◽  
Present Measurement ◽  
X Ray ◽  
Fundamental Experiment

In this study, a new portable X-ray stress analyzer was designed and manufactured. The purpose of its use is to evaluate the rolling contact fatigue damage in rails for establishing an effective rail maintenance method. An image plate was used in this analyzer for detecting diffracted X-ray beams. The cosα method was adopted for X-ray stress analysis from X-ray diffraction data. A fundamental experiment was made first for examning the present measurement system. Residual stresses in rails used in service for six years were also investigated in this study.

scholarly journals Use of Barkhausen noise for residual stress definition after diamond smoothing of high-pressure branch pipes

2020 ◽  
Vol 2020 (3) ◽  
pp. 24-31
Author(s):  
Semen Zaides ◽  
Artem Mashukov
Keyword(s):  
Residual Stress ◽  
High Pressure ◽  
Residual Stresses ◽  
Great Depth ◽  
Barkhausen Noise ◽  
Ray Method ◽  
X Ray ◽  
Valve Unit ◽  
Definition Of ◽  
Parameter Deformation

The results of residual stress definition after a valve unit diamond smoothing of high-pressure fittings are shown. In the paper there is used Barkhausen noise method allowing the definition of the residual stress level at a great depth as compared with the X-ray method. There is presented a procedure for the definition of residual stresses according to a ratio of a magnetoelastic parameter – deformation. The advantage of the diamond smoothing as a method of FSD allowing the decrease of tensile residual stresses and the increase compression stresses on a contact surface of fittings units is shown.

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