Plastic deformation analysis in machining of Inconel-718 nickel-base superalloy using both experimental and numerical methods

Surface region plastic deformation of Inconel-718 nickel-base superalloy workpieces was evaluated when machined under orthogonal cutting conditions at various cutting speeds. Plastic deformation analysis was accomplished by determining the residual stress and plastic strain distributions in the surface region. The residual stresses were tensile and maximum near the surface and decreased in magnitude with an increase in depth beneath the machined surface. Similarly, the plastic strains were maximum near the surface and decreased with an increase in depth beneath the machined surface. In addition, a finite element simulation of orthogonal machining was carried out for predicting the residual stress and plastic strain distribution. In general, the trend of the curves predicted by the finite element model was similar to those found experimentally.     

Note on the form of wear laws

The effect of cutting speed and tool wear land length on the plastic strain distribution in the surface region of annealed 18% Ni maraging steel machined under lubricated and unlubricated conditions is determined by using the grid technique.The results show that the magnitude of the plastic strains in the surface region and the depth of the plastically deformed layer increase with an increase in the cutting speed or the tool wear land length or both. The presence of the lubricant in the cutting region results in considerable reduction in the subsurface deformation.     

Analysis of the forming process of sintered powder metals by a rigid-plastic finite-element method

A finite-element method for analyzing plastic deformation of sintered powder metals is developed. To give a theoretical basis, a variational principle for rigid-plastic deformation of porous metals is derived. The effect of the change in density during plastic deformation due to expansion or contraction of the internal pores is accommodated to the rigid-plastic finite-element method. As an example of analysis, plane-strain continuous rolling of sintered powder plates is treated. The distributions of density, strain, strain rate and stress in the plate and the pressure distribution over the roll surface are calculated. It is shown that the deformation behaviour of sintered powder metals is significantly influenced by the initial density.     

变载荷作用下柔性关节板弹簧的大变形分析与强度计算

提出一种由气缸驱动的柔性机械手关节,关节采用板弹簧作为骨架。板弹簧的变形等效于自由端受特殊变载荷作用的弹性悬臂梁的大变形,其特殊变载荷是一个方向和大小都随气缸压力而变化的载荷。建立了悬臂梁静态变形的微分方程,采用简单的微分计算方法得出不同气缸压力下板弹簧任意位置的变形倾角、变形位移及应力的数值解。绘制其变形曲线和应力曲线,分析板弹簧的变形和应力分布情况,并校核了板弹簧最大应力处的强度。     

圆柱面过盈连接的应力分析

综合以往轴毂过盈连接分析中,只考虑了弹性变形的问题,在此基础上,进一步分析轴毂结构及配合过盈量对应力的影响,以及在怎样的条件下导致其发生塑性变形。根据屈瑞斯卡塑性条件,找出过盈连接由弹性变形过渡到塑性变形的条件,推导了在弹性与塑性情况下连接体内的应力计算公式,完善和丰富过盈配合的应力分析理论。计算实例分析了轴毂结构参数对许用过盈量的影响规律,并通过对毂内应力的分析,发现随着过盈量的增加,毂内塑性区变大,按弹性变形和按弹塑性变形计算的应力结果的差异变大。     

Subsurface plastic deformation in machining annealed red brass

The effect of cutting speed and tool geometry on the plastic deformation in the surface region of annealed red brass machined orthogonally under lubricated and unlubricated conditions is determined using the grid technique and metallography.The results show that the magnitude of the plastic deformation in the surface region and the depth of the work-hardened layer increase with a decrease in the cutting speed or the tool rake angle. Change in the tool wear land length produces a lesser change in the subsurface deformation than that observed to be due to a change in the other cutting parameters.The presence of the lubricant in the cutting region results in a considerable reduction in the subsurface damage.     

Thermal modeling of friction stir welding of stainless steel 304L

This paper presents a numerical model, based on the displacement of one point of the material flow relative to a fixed reference point, in order to formulate the heat generation during friction stir process and thereby calculate the temperature difference between advancing and retreating sides. This model considers frictional heating dependent on both the temperature and the velocity of the tool, as well as heat generation due to plastic deformation dependent on temperature, and assumes that friction heat at high temperature was replaced by heat generation due to plastic deformation. The heat generated by plastic strain energy dissipation in thermomechanically affected zone is calculated by a new technique, and the convection heat transfer coefficient and the sticking state parameter are considered as a function of temperature. Finally, the thermal equations are solved using a nonlinear finite element code ABAQUS. The numerical results correctly showed the asymmetric nature of temperature distributed at different sides of the weld line which have good agreement with experimental data that are presented in the literature.     

Subsurface characteristics of an abraded low carbon steel

Ductile metals commonly exhibit plastic deformation at and near the worn surface and their flow behaviour at large strains has a clear effect on wear resistance. In this study, the characteristics of the near-surface region of a ferritic-pearlitic steel (0.2% C, 1.2% Mn), subjected to abrasive wear tests, were examined. Wear tests were performed under different loads by rubbing the specimens on sliding 60 mesh Al₂O₃ abrasive band. The metallographic technique used to determine the magnitude of plastic deformation was based on measurement of the displacements of pearlite bands. The hardness of the plastic deformation zone was determined by performing ultramicrohardness tests along ferrite bands with a Vickers indenter. Microscopic examinations of the near-surface regions revealed the wear mechanism to be ploughing and the deformation mechanism to be cross-slip. It was observed that plastic strain (more than 6) occurred on the abraded surface, and increased the hardness to about 1.5 times the original value. The strain and hardness gradient extended to a larger depth into the bulk with increasing wear test load. It is concluded that the wear resistance of the investigated steel increases by work hardening of the near-surface region which is required to consume high energy for abrasion, during sliding. Ultramicrohardness measurements performed on worn specimens revealed high hardness, as the indent size decreased. The indentation size-hardness relation was explained by a dislocation model incorporating geometrically necessary dislocations due to the presence of strain gradients in the deformation region around the indent.     

Design of an Orthodontic Torque Simulator for Measurement of Bracket Deformation

The design and testing of an orthodontic torque simulator that reproduces the effect of archwire rotation on orthodontic brackets is described. This unique device is capable of simultaneously measuring the deformation and loads applied to an orthodontic bracket due to archwire rotation. Archwire rotation is used by orthodontists to correct the inclination of teeth within the mouth. This orthodontic torque simulator will provide knowledge of the deformation and loads applied to orthodontic bracket that will aide clinicians by describing the effect of archwire rotation on brackets. This will also impact that design on new archwire\bracket systems by providing an assessment of performance. Deformation of the orthodontic bracket tie wings is measured using a digital image correlation process to measure elastic and plastic deformation. The magnitude of force and moments applied to the bracket though the archwire is also measured using a six-axis load cell. Initial tests have been performed on two orthodontic brackets of varying geometry to demonstrate the measurement capability of the orthodontic torque simulator. The demonstration experiment shows that a Damon Q bracket had a final plastic deformation after a single loading of 0.022 mm while the Speed bracket deformed 0.071 mm. This indicates that the Speed bracket plastically deforms 3.2 times more than the Damon Q bracket for similar magnitude of applied moment. The demonstration experiment demonstrates that bracket geometry affect the deformation of orthodontic brackets and this difference can be detected using the orthodontic torque simulator.     

Subsurface plastic deformation in machining 6Al-2Sn-4Zr-2Mo titanium alloy

The effect of cutting speed and tool geometry on the plastic deformation in the surface region of 6242 titanium alloy machined orthogonally under lubricated and unlubricated conditions is determined using the grid technique and metallography.The results show that the magnitude of the plastic deformation in the surface region and the depth of the work-hardened layer increase with an increase in the cutting speed or the tool wear land length.The presence of the lubricant in the cutting region results in a considerable reduction in the subsurface damage.     

Possibilities of magnetic inspection of plastic deformations preceding failures of low-carbon steels constructions

The possibility of magnetic inspection of plastic deformations preceding the failure of strained steel constructions was studied by locally magnetizing them with an attachable electromagnet. Field dependences of the differential magnetic permeability of a plate made of steel 09Γ2 on the applied and residual stresses were determined. Critical fields of 90° and 180° domain-wall motion at different degrees of deformation were calculated using a model taking into account the contribution of these domain walls to magnetization reversal processes. Dependences of the coercive force and residual magnetization of the plate on the applied and residual stresses, which were measured using a SIMTEST portable magnetic measuring system, are reported.     

Microscopic approach of powder compaction using finite element method

An approach for simulating microscopic densification behaviour of powder particles in compaction using a finite element method is proposed. In this method, the contacts between powder particles during the compaction are detected, and plastic deformation of the particles is calculated by the finite element method for a porous metal. The finite element mesh is generated by connecting the centres of the particles in contact. It is assumed that the finite elements are porous metals having an average relative density calculated from the volumes of the powder and pore inside the element. The elements are classified into the triangular and quadrilateral ones used in the conventional finite element methods and a linear one for the simple compression. The accuracy of the stiffness for plastic deformation of the particles is improved by applying the finite element method. The calculated plastic deformation of powder particles in plane-strain compaction is compared with that for a model experiment using aluminium rods.     

乙烯压缩机机座异常变形的分析及防治

采用有限元数值模拟和模型试验方法，分析某炼油厂乙烯压缩机机座箱体侧板异常变形产生的原因，证实机座箱体变形是由于箱体内冷凝水结冰体积膨胀导致侧板塑性变形长期累积的结果。分析结果表明，正常工作条件下(排除结冰因素)机座箱体的变形不会继续发展，且不影响压缩机的正常运行，建议保留到下次大修时再更换机座箱体，且新箱体顶板上不再开孔。     

The influence of strain hardening of polymers on the piling-up phenomenon in scratch tests: Experiments and numerical modelling

The aim of this study was to relate the scratching behaviour of polymers to their mechanical properties. A thermosetting resin (CR39) and a thermoplastic polymer (PMMA) were studied using a microscratch tester allowing in situ observation of the contact area. These two polymers exhibit different elastic and viscoplastic properties, the main difference being the large ability of CR39 to strain harden, whereas PMMA softens. A spherical indenter was used to vary the level of deformation imposed on the samples. The response was initially elastic, then viscoelastic and finally mainly viscoplastic with increasing penetration of the indenter into the material. The two polymers displayed the same response for small levels of deformation, while at larger strains PMMA showed more pronounced plastic behaviour. The origin of this difference in behaviour was investigated by means of a three dimensional finite element analysis. The rheology of PMMA and CR39 was simplified and modelled by assuming linear elastic behaviour and a viscoplastic law taking into account their strain hardening capacity at high strains. Strain hardening was found to be a key factor to correctly model the material flow around the indenter. The response of the polymers was governed by the ratio between the plastic and elastic strains involved in the deformation in the contact region. In first approximation, the representative strain was imposed mainly by the geometry of the indenter, while the elastic deformation was controlled by the mechanical properties of the material, a larger strain hardening leading to a greater elastic deformation and a lower plastic strain thus a better scratch resistance of the specimen.     

Bursting failure prediction in tube hydroforming processes by using rigid–plastic FEM combined with ductile fracture criterion

The most common failure in tube hydroforming is the bursting failure due to excessive thinning of large deformation. To evaluate the forming limit of hydroforming processes, the Oyane's ductile fracture integral I was introduced and calculated from the histories of stress and strain according to every element by using the rigid–plastic finite element method. The region of fracture initiation and the forming limit for three hydroforming processes, such as a tee extrusion, an automobile rear axle housing, and a lower arm under different forming conditions are predicted in this study. Also it is shown that the material parameters used in the ductile failure can be obtained from the experimental forming limit diagram. From the results, the prediction of the bursting failure and the plastic deformation for the three hydroforming examples demonstrates to be reasonable so that this approach can be extended to a wide range of practical tube hydroforming processes.     

冷轧摩擦热计算及温升模型研究

冷轧时轧件塑性变形热和摩擦热是导致轧件温度升高的两个主要原因。本文采用包含滑动摩擦和粘着摩擦在内的混合摩擦模型精确地计算了轧制区的摩擦热，综合考虑轧件塑性变形热，推导了轧件温升计算公式。     

Large deflection analysis of elastoplastic plate in steady continuous four-roll bending process

This paper presents a mathematical model to simulate the mechanics in a steady continuous bending mode for four-roll thin plate bending process. The differential equations governing the large deflection bending of elastic-perfectly plastic thin plate are derived by modelling the loading and unloading deformation of the operational process. Through a semi-analytical solution of the system equations, the physical quantities of (i) the deformation and stress resultants of bend plate, (ii) the springback, (iii) the shift of contact-angle of bend plate with rolls, (iv) the applied forces on rolls, (v) the bending torque and power, and (vi) the position of the operative side roll, etc., associated with bending of a plate to an anticipated curvature, for single-pass bending operation, are predicted and discussed.     

Plastic deformation of surface layer during rigid cylinder rolling and sliding

Steady-state plastic deformation of the surface layer induced by the rolling and sliding of a rigid cylinder is investigated using ideal plastic plane strain theory taking into consideration contact friction. The plastic region and length of the contact arc related to the forces and the moment applied to the cylinder are calculated. Results are studied for rolling friction theory in the case of large contact loads and for surface plastic-layer deformation to increase the wear resistance and fatigue strength of machine parts.     

粗糙体变形特性对接触过程的应力与应变的影响

运用W-M函数生成分形粗糙表面,建立一个新的双粗糙体接触模型,采用有限元方法模拟仿真了在粗糙体不同变形特性条件下的接触过程,并分析了接触表面的应力分布及不同接触位置的塑性应变随深度的变化规律．结果表明双粗糙接触表面的应力主要集中在个别的较高微凸体上,其应力最大值出现在微凸体肩部区域的位置;等效塑性应变在不同位置沿深度的变化,呈现出不同的规律,微凸体顶部区域沿深度方向的最大等效塑性应变均发生在次表层,材料表层下的塑性应变将会导致材料表层中的夹杂或微观缺陷周围萌生微孔和裂纹源,对比不同变形特性的模型,得出弹塑性一刚体模型的最大应力及应变值都大于弹塑性一弹塑性模型。