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.

Prediction of residual stresses in roller burnished components : a finite element approach

Surface finish is an important factor in creating the durable metal components, and fatigue strength can be improved if compressive residual stresses are produced in the surface. Burnishing is a finishing process and compressive residual stresses are induced during the process. The present study of minimizing the surface roughness based on the experimental work, and finite element model was developed to evaluate the analytical results. Commercial purity Mild Steel and Aluminium were selected as work specimens and a high carbon high chromium roller was used as a tool for the burnishing process.

Sheet forming simulation for AHSS components in the automotive industry

The trend in the automotive industry towards new advanced high strength steels (AHSS), combined with the ongoing reduction in program lead times have increased the need to get tool designs right, first time. Despite the fact that the technology used by sheet metal stamping companies to design and manufacture tooling is advancing steadily, finding optimal process parameters and tool geometries remains a challenge. Consequently, there has been a transition from designs based largely on trial and error techniques and the experience of the stamping engineer, to the increased use of virtual manufacturing and finite element (FE) simulation predictions as an indispensable tool in the design process. This work investigates the accuracy of FE techniques in predicting the forming behavior of AHSS grades, such as TRIP and dual phase, as compared to more commonly used conventional steel grades. Three different methods of simulation, one-step, implicit and explicit techniques, were used to model the forming process for an automotive part. Results were correlated with experimental strain and thickness measurements of manufactured components from the production line.

Statistical analysis of finite element modeling in sheet metal forming and springback analysis

This work focuses on development of a method to statistically study forming and springback problems of TRansformation Induced Plasticity (TRIP) through an industrial case study. A Design of Experiments (DOE) approach was used to study the sensitivity of predictions to four user input parameters in implicit and explicit sheet metal forming codes. Numerical results were compared to experimental measurements of parts stamped in an industrial production line. The accuracy of forming strain predictions for TRIP steel were comparable with conventional steel, but the springback predictions of TRIP steel were far less accurate. The statistical importance of selected parameters for forming and springback prediction is also discussed. Changes of up to ±10% in Young's modulus and coefficient of friction were found to be insignificant in improving or deteriorating the statistical correlation of springback accuracies.

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 modeling of a generic stemless hip implant design in comparison with conventional hip implants

In this study, the finite element modeling and comparison of the stress and strain analyses were carried out for three different structures that are intact bone, stemless implant and stemmed one. Currently proposed stemless design studied here is the generic concept of stemless implant. This generic stemless implant reconstruction was numerically compared to the conventional stemmed implant and also to the intact bone as control solution. Two loading conditions were applied to the most proximal part of the models, while the most distal part was fixed for all degrees of freedom. The models were divided into two regions and studied along two paths of medial and lateral aspect. The results of this study showed that the stemless implant had less deviation from the control solution of the bone in all regions and in both loading conditions, comparing to the large deviation of the stemmed implant from the intact bone. However, it was shown that the fixation of this type of implant and its effect on sub-trochanter region must be carefully considered for designing the final product of any specific design of stemless implant.

Hybrid special finite element method for bi-material crack

In the paper, two novel 2-D hybrid special finite elements each containing an interfacial edge crack, which lies along or vertical to the interface between two materials, are developed. These proposed elements can assure the high precision especially in the vicinity of crack tip and provide a better description of its singularity with only one hybrid element surrounding one interfacial crack, thus, the numerical modeling of fracture analysis on bi-material crack can be greatly simplified. Numerical examples are provided to demonstrate the validity and versatility of the proposed method.

Fracture analysis of spot-welds with edge cracks using 2-D hybrid special finite element

This paper employed a systematic analysis using a 2-D hybrid special finite element containing an edge crack in order to describe the fracture behavior of spot-welds in automotive structures. The 2-D hybrid special finite element is derived form a mixed formulation with a complex potential function with the description of the singularity of a stress field. The hybrid special finite element containing an edge crack can give a better description of its singularity with only one hybrid element surrounding one crack. The advantage of this special element is that it can greatly simplify the numerical modeling of the spot welds. Some numerical examples demonstrate the validity and versatility of the present analysis method. The lap-shear, lap-tension and angle-clip specimens are analyzed and some useful fracture parameters such as the stress intensity factor and the initial direction of crack growth are obtained simultaneously.

Analytical solutions and finite element modelling of deep drawing process for cylindrical metal cups

Analytical modelling of deep drawing process is of value in preliminary process design to illustrate the influence of major variables including friction and strain hardening on punch loads, cup dimensions and process limits. In this study, analytical models including theoretical solution and a series of finite element models are developed to account for the influences of process parameters including friction coefficient, tooling geometry and material properties on deep drawing of metal cups. The accuracy of both the theoretical and finite element solutions is satisfactory compared with those from experimental work.