Papers by Keyword: Distortion

Abstract: This paper analyzes the possibility to induce residual compressive stresses utilizing deep rolling in a long, slim steel workpiece that is profile ground and that resembles a linear guide rail. These intentionally caused residual compressive stresses at the side surfaces of the workpiece are intended to counteract the distortion due to residual stresses in the V-groove of the guide rail induced by grinding. A finite element model was prepared based on the initial state of the workpiece. The amount of respective stresses depended on the load intensity and duration of the process. The experimental data regarding the residual stress profiles due to the deep rolling process and the resulting workpiece distortion were used to validate the simulation, so that an adjustment or a calibration of the thermometallurgical and thermomechanical material data was possible. The key findings are the numerical design of appropriate strategies for the distortion potential induction, the experimental distortion results, knowledge on the mechanical treatment by deep rolling, and the successful modeling of the mechanical treatment and the process strategy.

Abstract: During heat treatment of machine parts and tools, besides the usual task of ensuring a high complex of mechanical and operational properties, there is a problem of distortion of products in the process of heat treatment and the need for editing operations (which are carried out manually and require significant labor costs). The known methods do not solve the problem of removing distortion for thin-walled parts of the ring shape completely. This paper shows the technical possibility of using the energy of a constant magnetic field for the "internal" straightening of products during heat treatment in the temperature range of super-plasticity of transformation. The use of special equipment makes it possible to eliminate virtually the distortion of thin-walled parts of the ring shape and to improve their mechanical properties.

Abstract: In this study, the GMAW parameters for welding of A36 mild steel have been investigated to get the minimum of distortion. The type of welded joint used was square groove T-joint fillet weld with filler wire ER70S-6. The welding current and the welding speed were selected as input parameters while the response used was distortion (longitudinal bending distortion and angular distortion). Taguchi method was used to determine optimal welding parameters which the minimum distortion. Design of experiment was set two factors with three level in each factor and three replication, so the L₉ Taguchi’s orthogonal array was applied. The minimum conditions were determined using S/N ratio with a quality character of smaller is better (SB). In addition, to determine the significance of the welding parameters used ANOVA. The results show that the welding current of 170 A and the welding speed of 4.0 mm/s were obtained as the minimum of longitudinal bending distortion and angular distortion. Based on analysis of variance, the welding current was a parameter that greatly affects the longitudinal bending distortion with the percentage contribution of 64.36% while angular distortion was strongly influenced by welding speed parameter with the percentage contribution of 53.38%.

Abstract: The laser metal deposition is an advanced manufacturing technology enabling the production of large-sized parts and partially or completely elimination of machining and welding. The process is characterised by a non-uniform local heating of the buildup leading to a stress distribution, which may exceed the yield strength of the material and leads to loss of dimensional accuracy. The interlayer dwell time has a strong influence on the temperature field. The effect of the interlayer dwell time on the distortion and the stress distribution during laser metal deposition of a single-pass wall on the edge of 2 mm thick plate was studied experimentally and numerically. The deposited material was IN625 and the substrate material was AISI 316. A decrease of the residual displacement, due to a uniform shrinkage after the deposition of the last layer and a lower level of the residual compressive longitudinal plastic strain, has been observed in the studies without a dwell time. The peak increment of the free edge displacement corresponds to the first layer and hence the subsequent layers will be deposited on the already plastically deformed buildup. The tensile residual longitudinal stress near the top of the buildup and transverse stress near the edges of the buildup is higher than yield strength in the studies with dwell time.

Abstract: This article concerns distortion of a workpiece after induction-hardening under various conditions. It focuses particularly on the effects of quenching water temperature, PAG polymer concentration and the rotation speed of the workpiece during induction hardening. Electrical as well as non-electrical quantities which affect the process were monitored. They included the current passing through the inductor, the power frequency, quenching water temperature, the flow rate of the quenchant through the spray-quench device, the speed of rotation of the workpiece and some others. The workpiece was a cylinder 70 mm in length which contained a drilled off-axis through hole. Prior to hardening, dimensions of the workpiece and the hole were measured on three planes set in different distances from the bottom face. The measurement was repeated after induction hardening and the findings are reported in this article. Post-process hardness was measured on the cylindrical surface of the workpiece. Hardening depths obtained with different quenchants were measured.

Abstract: The research purpose is to upgrade the mathematical modelling and computer simulation of quenching of steel. Based on theoretical analyze of physical processes which exist in quenching systems the mathematical model for steel quenching is established and computer software is developed. The mathematical model of steel quenching is focused on physical phenomena such as heat transfer, phase transformations, mechanical properties and generation of stresses and distortions. Physical properties that were included in the model, such as heat conductivity coefficient, heat capacity and surface heat transfer coefficient were obtained by the inversion method based on Jominy test results. The numerical procedure is based on finite volume method. By the developed algorithm, 3D situation problems such as the quenching of complex cylinders, cones, spheres, etc., can be simulated. The established model of steel quenching can be successfully applied in the practical usage of quenching.

Abstract: It’s well known that the vehicle fuel economy is improved by reducing the weight of their structural and mechanical components. Therefore, there is a demand of bearing race with thin thickness for weight reduction. But, this thickness reduction also causes a large oval distortion in bearings after Heat Treatment (HT). The factors affecting the HT distortion are extremely complicated, which makes it difficult to do rectification only by experimental analysis. There is also a limitation in numerical analysis due to the lack of workable model for HT distortion. Therefore, the aim of this study is to identify the effective factors of HT distortion by experimental approach in order to build suitable numerical simulation model that can estimate HT distortion. The material used in this study is a conventional case-hardened steel (Fe-0.4mass%C-Cr-Mn). The ring with the diameter of 100mm is heat treated and quenched. The resulting HT distortion is evaluated by measurement of maximum and minimum diameter of the race. A jig was developed to correct the ring shape during heat treatment, which helped in identifying that the quenching affects more than 50% of HT distortion. From these results, we developed a cooling equipment to reproduce inhomogeneous cooling rate by controlling oil flow toward the exterior of the ring. The quenching with this equipment reveals that inhomogeneous flow with opposite side (0 degree and 180 degree) reproduces a large oval distortion. The data obtained from the experimental analysis is suitable for developing the numerical model for HT distortion.

Abstract: Calculation of the cross-sectional properties of the concrete box-girder with two-cells using Vlasov`s theory and Generalized Beam Theory. Calculation of the internal forces of the St. Venant torsion, the warping torsion, the antisymmetrical and the symmetrical distortion on the basis analogy with beam on the elastic foundation loaded by transverse actions and tension force at the end of the beam. Creating of influence lines of torsion, antisymmetrical distortion and symmetrical distortion internal forces of large concrete cable-stayed bridge with continuous box-girders with two spans. The application for real reinforced concrete Harp bridge over pond Jordán near Tábor in Czech Republic is investigated. Evaluation of internal lines for action according to Eurocode EN 1991-2.

Abstract: Due to the occurrence of residual stresses during manufacturing, parts made of carbon fibre reinforced plastics exhibit considerable shape distortions. A finite element simulation tool to predict these distortions is developed in this work. All simulations are conducted using the finite element software LS-DYNA. For an L-profile, different finite element formulations are compared with regard to run time and accuracy. Having identical mesh topology, solid and thick shell elements show comparable run times and results. The layered composition of thick shells leads to a reduction of computational cost, but also increases the error concerning the predicted distortion angle. Finally, employing the insights gained from the mesh study, an actual car body part is studied for the purpose of validation.

Abstract: Welding is one of the joining processes and it has been widely used, especially for steel welded structure in off-shore, pipeline or ship construction. Advantages of the welding joint are inexpensive, process joining can be done quickly and can produce light structure compared to other joining processes. One of welding techniques mostly used for joining steel construction is flux cored arc welding (FCAW). The commonly problems arise in this welding technique are distortion and low resistance of crack propagation. The aim of this study is to minimize distortion and to increase fatigue crack growth resistance of weld joint.In this research, FCAW welding was conducted without preheat and the other was preheated around welding area with temperature of 200 °C. Each of temperature welding process was measured using data acquisition. After completing the welding process, a sequence of experiment was conducted including chemical compositions, distortion and fatigue test. Result of this research shows that preheat temperature of 200 °C can decrease distortion and improve fatigue performance.