Residual Stress Prediction for Part Distortion Modeling
Date Published: 2006-09-12
Paper Number:2006-01-3171
DOI: 10.4271/2006-01-3171
Citation:
Marusich, T., Usui, S., Lankalapalli, S., Saini, N. et al., "Residual Stress Prediction for Part Distortion Modeling," SAE Technical Paper 2006-01-3171, 2006, doi:10.4271/2006-01-3171.
Author(s):
T. D. Marusich - Third Wave Systems
S. Usui - Third Wave Systems
S. Lankalapalli - Third Wave Systems
N. Saini - Third Wave Systems
L. Zamorano - Third Wave Systems
A. Grevstad - Third Wave Systems
Residual stresses and part distortion are major obstacles to time-to-market, reduced scrap, and high part quality in metal machining. Aerospace monolithic structures suffer from distortions that hamper assembly operations. Automotive powertrain components have high flatness-tolerance surfaces that maintain fuel efficiency while lowering emissions. Problems persist because industry lacks a capability to predict machining induced residual stresses and part distortion.
One method of comprehensive distortion analysis is application of the finite element method (FEM). Here, a three-dimensional FEM model is presented that includes fully adaptive unstructured mesh generation, tight thermo-mechanical coupling, deformable tool-chip-workpiece contact, momentum effects at high speeds and constitutive models appropriate for high strain rate, and finite deformation analysis that predicts machining induced residual stresses. A complementary capability to translate the machining induced residual stress results and incorporate pre-existing stresses to a holistic part level analysis for part distortion prediction will be discussed.
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