Finite element analysis of residual stresses in metallic coatings through a compound casting

Al and Mg alloys are widely used in industry as main lightweight alloys. They have excellent properties, such as low density, high ductility, and high specific strength, and so on. Generally speaking, Mg alloys are better than Al alloys. However the corrosion of Mg alloys is much more difficult to control compared Al alloys. Therefore to combine these two lightweight alloys, a composite-like structure is an ideal solution since Al alloys can be used as protective coatings for Mg alloys. Compound casting is a realistic technique to get this coating system. In the current study, we numerically study the compound casting using finite element method (FEM) to make these two alloys, a composite-like structure, satisfy requirements to resist corrosion required from industry, in which the aluminum layer is acting as a protective coating for the magnesium substrate. Several finite element models have been developed by using the birth and death element technique and we focus on compound casting-induced residual stresses in the compounded structure. The numerical results obtained from the proposed finite element models show the distribution profiles of thermal residual stresses. We found the major factors influencing the residual stresses are the temperature to pre-heating the Al substrate and the thickness of Mg deposits. © (2014) Trans Tech Publications, Switzerland.

Object oriented finite element analysis: a distributed approach to mesh generation

The object-oriented finite element method (OOFEM) has attracted the attention of many researchers. Compared with the traditional finite element method, OOFEM software has the advantages of maintenance and reuse. Moreover, it is easier to expand the architecture to a distributed one. In this paper, we introduce a distributed architecture of a object-oriented finite element preprocessor. A comparison between the distributed system and the centralised system shows that the former, presented in the paper, greatly improves the performance of mesh generation. Other finite element analysis modules could be expanded according to this architecture.

Experimental investigation and finite element analysis for the study of residual stresses in roller burnished components

Burnishing is a surface modification process, which involves plastic deformation of the material at the surface of the component due to the application a highly polished and hard roller, under pressure. This results in the improvement of the surface finish of the component and induces residual compressive stresses on the surface of the component. The present work deals with the optimization of the burnishing force for the best surface finish, at constant speed and feed, for Aluminium and Mild steel workpieces. A 3dimensional finite element model is proposed for the simulation of the burnishing process, and the analysis is carried out at the optimum force determined experimentally. The induced compressive stress in the components is determined from the finite element analysis and this value is then compared with the results obtained from X-ray diffraction technique.

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.

Finite element analysis of an axi-symmetric forward spiral extrusion of Mg-1.75Mn alloy

A potential severe plastic deformation process known as axi-symmetrical forward spiral extrusion (AFSE) has been studied numerically and experimentally. The process is based on the extrusion of cylindrical samples through a die with engraved spiral grooves in a near zero shape change manner. The process was simulated using a three dimensional finite element (FE) model that has been developed using commercial software, ABAQUS. In order to verify the finite element results, hot rolled and annealed samples of the alloy were experimentally processed by AFSE. The required extrusion forces during the process were estimated using the FE model and compared with the experimental values. The reasonable agreement between the FE results and experimental data verified the accuracy of the FE model. The numerical results indicate the linear strain distribution in the AFSE sample is only valid for a core concentric while the strain distribution in the vicinity of the grooves is non axi-symmetric. The FE simulation results from this research allows a better understanding of AFSE kinematics especially near the grooves, the required extrusion force and the resultant induced strain distribution in the sample. To compare the mechanical properties of the Mg-1.75Mn alloy before and after the process, a micro shear punch test was used. The tests were performed on samples undergoing one and four passes of AFSE. After four passes of AFSE, it was observed that the average shear strength of the alloy has improved by about 21%. The developedfinite element model enables tool design and material flow simulation during the process.

Finite element analysis of plastic deformation in variable lead axisymmetric forward spiral extrusion

A modified axisymmetric forward spiral extrusion (AFSE) has been proposed recently to enhance the strain accumulation during the process. The new technique is called variable lead axisymmetric forward spiral extrusion (VLAFSE) that features a variable lead along the extrusion direction. To assess the effect of design modification on plastic deformation, a comprehensive study has been performed here using a 3D transient finite element (FE) model. The FE results established the shear deformation as the dominant mode of deformation which has been confirmed experimentally. The variable lead die extends strain accumulation in the radial and longitudinal directions over the entire grooved section of the die and eliminates the rigid body rotation which occurs in the case of a constant lead die, AFSE. A comparison of forming loads for VLAFSE and AFSE proved the advantages of the former design in the reduction of the forming load which is more pronounced under higher frictional coefficients. This finding proves that the efficiency of VLAFSE is higher than that of AFSE. Besides, the significant amount of accumulated shear strain in VLAFSE along with non-axisymmetric distribution of friction creates a surface feature in the processed sample called zipper effect that has been investigated. © 2012 Springer Science+Business Media New York.

Variation of yield loci in finite element analysis by considering texture evolution for AA5042 aluminum sheets

 Yield function has various material parameters that describe how materials respond plastically in given conditions. However, a significant number of mechanical tests are required to identify the many material parameters for yield function. In this study, an effective method using crystal plasticity through a virtual experiment is introduced to develop the anisotropic yield function for AA5042. The crystal plasticity approach was used to predict the anisotropic response of the material in order to consider a number of stress or strain modes that would not otherwise be evident through mechanical testing. A rate-independent crystal plasticity model based on a smooth single crystal yield surface, which removes the innate ambiguity problem within the rate-independent model and Taylor model for polycrystalline deformation behavior were employed to predict the material’s response in the balanced biaxial stress, pure shear, and plane strain states to identify the parameters for the anisotropic yield function of AA5042.

Experimental and finite element analysis of machinability of AL-6XN super austenitic stainless steel

This paper presents a finite element cutting modelbased on physical microstructure to investigate the thermomechanicalbehaviour of AL-6XN Super AusteniticStainless Steel in the primary shear zone. Frozen chip rootsamples were created under dry turning operation to observethe plasticity behaviour occurring in the shear zones to comparewith the model for analysis. Chip samples were generatedunder cutting velocities at 65 and 94 m/min, feed rate at0.2 mm/rev and depth of cut at 1 mm. Temperature on thecutting zone was recorded by infrared thermal camera.Secondary and backscatter electron detectors were used toinvestigate the deformed microstructure and to calculate theplastic strain. Experimental results showed the formation ofmicrocracks (build-up edge triggers) at the chip root stagnationzone of both samples. The austenite phase patterns wereevident against the cutting tool tip in the stagnation zone of thechip root fabricated at 65 m/min. The movement of thesepatterns caused the formation of the slip lines within thegrains. The backscatter diffraction maps showed the formationof special grain boundaries within the slip lines, workhardeninglayer and in the chip region. Strain measurementsin the microstructures of the chip roots fabricated at 94 and65 m/min showed high values of 6.5 and 5.7 (mm/mm) respectively.The finite element model was used to measure thestress, strain, temperature and chip morphology. Numericalresults were compared to the outcomes of the experimentalwork to validate the finite element model. The model validatingprocess showed good agreement between theexperimental and numerical results, and the error values werecalculated. For a 94- and 65-m/min cutting speeds, 7.5 and5.2% were the errors in the strain, 3 and 2.5% were the error inthe temperature and 4.7 and 6.8% were the error in the shearplane angles.

The design and development of an integrated system for object-oriented finite element computing

Finite Element Method (FEM) is widely used in Science and Engineering since 1960’s. The vast majority of FEM software is procedure-oriented. However, this conventional style of designing FEM software encounters problems in maintenance, reuse, and expansion of the software. Recently the object-oriented finite element method attracts the attention of lots of researchers, and now there is a growing interest in this method. In this paper, the object-oriented finite element (OOFE) is briefly introduced. Then the design and development of an integrated OOFE system is described. A comparison of the integrated OOFE system and a procedure-oriented system shows that our OOFE system has many advantages.