A preliminary structural design procedure for laser beam welded airframe stiffened panels

Initial sizing procedures for aircraft stiffened panels that include the influence of welding fabrication residual process effects are missing. Herein, experimental and Finite Element analyses are coupled to generate knowledge to formulate an accurate and computationally efficient sizing procedure which will enable designers to routinely consider panel fabrication, via welding, accounting for the complex distortions and stresses induced by this manufacturing process. Validating experimental results demonstrate the need to consider welding induced material property degradation, residual stresses and distortions, as these can reduce static strength performance. However, results from fuselage and wing trade-studies, using the validated sizing procedure, establish that these potential reductions in strength performance may be overcome through local geometric tailoring during initial sizing, negating any weight penalty for the majority of design scenarios.

Thermomechanical Response of Variable Stiffness Composite Panels

Analysis of non-traditional Variable Stiffness (VS) laminates, obtained by steering the fiber orientation as a spatial function of location, have shown to improve buckling load carrying capacity of flat rectangular panels under axial compressive loads. In some cases the buckling load of simply supported panels doubled compared to the best conventional laminate with straight fibers. Two distinct cases of stiffness variation, one due to fiber orientation variation in the direction of the loading, and the other one perpendicular to the loading direction, were identified as possible contributors to the buckling load improvements. In the first case, the increase was attributed to the favorable distribution of the transverse in-plane stresses over the panel platform. In the second case, a higher degree of improvement was obtained due to the re-distribution of the applied in-plane loads. Experimental results, however, showed substantially higher levels of buckling load improvements compared with theoretical predictions. The additional improvement was determined to be due to residual stresses introduced during curing of the laminates. The present paper provides a simplified thermomechanical analysis of residual stress state of variable stiffness laminates. Systematic parametric analyses of both cases of fiber orientation variations show that, indeed much higher buckling loads could result from the residual stresses present in such laminates.

The development of a surface defect machining method for hard turning processes

Hard turning (HT) is a material removal process employing a combination of a single point cutting tool and high speeds to machine hard ferrous alloys which exhibit hardness values over 45 HRC. In this paper, a surface defect machining (SDM) method for HT is proposed which harnesses the combined advantages of porosity machining and pulsed laser pre-treatment processing. From previous experimental work, this was shown to provide better controllability of the process and improved quality of the machined surface. While the experiments showed promising results, a comprehensive understanding of this new technique could only be achieved through a rigorous, in depth theoretical analysis. Therefore, an assessment of the SDM technique was carried out using both finite element method (FEM) and molecular dynamics (MD) simulations.
FEM modelling was used to compare the conventional HT of AISI 4340 steel (52 HRC) using an Al2O3 insert with the proposed SDM method. The simulations showed very good agreement with the previously published experimental results. Compared to conventional HT, SDM provided favourable machining outcomes, such as reduced shear plane angle, reduced average cutting forces, improved surface roughness, lower residual stresses on the machined surface, reduced tool–chip interface contact length and increased chip flow velocity. Furthermore, a scientific explanation of the improved surface finish was revealed using a state-of-the-art MD simulation model which suggested that during SDM, a combination of both the cutting action and rough polishing action help improve the machined surface finish.

Multiscale simulation of nanometric cutting of single crystal copper and its experimental validation

In this paper a multiscale simulation study was carried out in order to gain in-depth understanding of machining mechanism of nanometric cutting of single crystal copper. This study was focused on the effects of crystal orientation and cutting direction on the attainable machined surface quality. The machining mechanics was analyzed through cutting forces, chip formation morphology, generation and evolution of defects and residual stresses on the machined surface. The simulation results showed that the crystal orientation of the copper material and the cutting direction significantly influenced the deformation mechanism of the workpiece materials during the machining process. Relatively lower cutting forces were experienced while selecting crystal orientation family {1 1 1}. Dislocation movements were found to concentrate in front of the cutting chip while cutting on the (1 1 1) surface along the View the MathML source cutting direction thus, resulting in much smaller damaged layer on the machined surface, compared to other orientations. This crystal orientation and cutting direction therefore recommended for nanometric cutting of single crystal copper in practical applications. A nano-scratching experiment was performed to validate the above findings.

Incipient plasticity in 4H-SiC during quasistatic nanoindentation

Silicon carbide (SiC) is an important orthopaedic material due to its inert nature and superior mechanical and tribological properties. Some of the potential applications of silicon carbide include coating for stents to enhance hemocompatibility, coating for prosthetic-bearing surfaces and uncemented joint prosthetics. This study is the first to explore nanomechanical response of single crystal 4H-SiC through quasistatic nanoindentation. Displacement controlled quasistatic nanoindentation experiments were performed on single crystal 4H-SiC specimen using a blunt Berkovich indenter (300 nm tip radius) at extremely fine indentation depths of 5 nm, 10 nm, 12 nm, 20 nm, 25 nm and 50 nm. Load-displacement curve obtained from the indentation experiments showed yielding or incipient plasticity in 4H-SiC typically at a shear stress of about 21 GPa (~an indentation depth of 33.8 nm) through a pop-in event. An interesting observation was that the residual depth of indent showed three distinct patterns: (i) Positive depth hysteresis above 33 nm, (ii) no depth hysteresis at 12 nm, and (iii) negative depth hysteresis below 12 nm. This contrasting depth hysteresis phenomenon is hypothesized to originate due to the existence of compressive residual stresses (upto 143 MPa) induced in the specimen by the polishing process prior to the nanoindentation

The prediction of process-induced deformation in a thermoplastic composite in support of manufacturing simulation

Digital manufacturing techniques can simulate complex assembly sequences using computer-aided design-based, as-designed' part forms, and their utility has been proven across several manufacturing sectors including the ship building, automotive and aerospace industries. However, the reality of working with actual parts and composite components, in particular, is that geometric variability arising from part forming or processing conditions can cause problems during assembly as the as-manufactured' form differs from the geometry used for any simulated build validation. In this work, a simulation strategy is presented for the study of the process-induced deformation behaviour of a 90 degrees, V-shaped angle. Test samples were thermoformed using pre-consolidated carbon fibre-reinforced polyphenylene sulphide, and the processing conditions were re-created in a virtual environment using the finite element method to determine finished component angles. A procedure was then developed for transferring predicted part forms from the finite element outputs to a digital manufacturing platform for the purpose of virtual assembly validation using more realistic part geometry. Ultimately, the outcomes from this work can be used to inform process condition choices, material configuration and tool design, so that the dimensional gap between as-designed' and as-manufactured' part forms can be reduced in the virtual environment.

Molecular dynamics simulation (MDS) to study nanoscale machining processes

Molecular Dynamics Simulations (MDS) are constantly being used to make important contributions to our fundamental understanding of material behaviour, at the atomic scale, for a variety of thermodynamic processes. This chapter shows that molecular dynamics simulation is a robust numerical analysis tool in addressing a range of complex nanofinishing (machining) problems that are otherwise difficult or impossible to understand using other methods. For example the mechanism of nanometric cutting of silicon carbide is influenced by a number of variables such as machine tool performance, machining conditions, material properties, and cutting tool performance (material microstructure and physical geometry of the contact) and all these variables cannot be monitored online through experimental examination. However, these could suitably be studied using an advanced simulation based approach such as MDS. This chapter details how MD simulation can be used as a research and commercial tool to understand key issues of ultra precision manufacturing research problems and a specific case was addressed by studying diamond machining of silicon carbide. While this is appreciable, there are a lot of challenges and opportunities in this fertile area. For example, the world of MD simulations is dependent on present day computers and the accuracy and reliability of potential energy functions [109]. This presents a limitation: Real-world scale simulation models are yet to be developed. The simulated length and timescales are far shorter than the experimental ones which couples further with the fact that contact loading simulations are typically done in the speed range of a few hundreds of m/sec against the experimental speed of typically about 1 m/sec [17]. Consequently, MD simulations suffer from the spurious effects of high cutting speeds and the accuracy of the simulation results has yet to be fully explored. The development of user-friendly software could help facilitate molecular dynamics as an integral part of computer-aided design and manufacturing to tackle a range of machining problems from all perspectives, including materials science (phase of the material formed due to the sub-surface deformation layer), electronics and optics (properties of the finished machined surface due to the metallurgical transformation in comparison to the bulk material), and mechanical engineering (extent of residual stresses in the machined component) [110]. Overall, this chapter provided key information concerning diamond machining of SiC which is classed as hard, brittle material. From the analysis presented in the earlier sections, MD simulation has helped in understanding the effects of crystal anisotropy in nanometric cutting of 3C-SiC by revealing the atomic-level deformation mechanisms for different crystal orientations and cutting directions. In addition to this, the MD simulation revealed that the material removal mechanism on the (111) surface of 3C-SiC (akin to diamond) is dominated by cleavage. These understandings led to the development of a new approach named the “surface defect machining” method which has the potential to be more effective to implement than ductile mode micro laser assisted machining or conventional nanometric cutting.

Injection moulding process optimization for microstructured parts production

Ao longo das últimas décadas, a micromoldação (u-moldação) por injeção de termoplásticos ganhou um lugar de destaque no mercado de equipamentos eletrónicos e de uma ampla gama de componentes mecânicos. No entanto, quando o tamanho do componente diminui, os pressupostos geralmente aceites na moldação por injeção convencional deixam de ser válidos para descrever o comportamento reológico e termomecânico do polímero na microimpressão. Por isso, a compreensão do comportamento dinâmico do polímero à escala micro bem como da sua caraterização, análise e previsão das propriedades mecânicas exige uma investigação mais alargada. O objetivo principal deste programa doutoral passa por uma melhor compreensão do fenómeno físico intrínseco ao processo da μ-moldação por injeção. Para cumprir com o objetivo estabelecido, foi efetuado um estudo paramétrico do processo de μ-moldação por injeção, cujos resultados foram comparados com os resultados obtidos por simulação numérica. A caracterização dinâmica mecânica das μ-peças foi efetuada com o objetivo de recolher os dados necessários para a previsão do desempenho mecânico das mesmas, a longo prazo. Finalmente, depois da calibração do modelo matemático do polímero, foram realizadas análises estruturais com o intuito de prever o desempenho mecânico das μ-peças no longo prazo. Verificou-se que o desempenho mecânico das μ-peças pode ser significativamente afetado pelas tensões residuais de origem mecânica e térmica. Estas últimas, resultantes do processo de fabrico e das condições de processamento, por isso, devem ser consideradas na previsão do desempenho mecânico e do tempo de serviço das u-moldações.

Randzonenveränderung beim Bohren und ihre Auswirkung auf Folgebearbeitungsverfahren

In der Praxis kommt es bei der spanenden Bearbeitung immer wieder zu großen Standwegunterschieden identischer Werkzeuge bei vordergründig identischen Bearbeitungsrandbedingungen. Insbesondere bei Fertigungsschritten, die das Bohren als Vorbearbeitung erfordern, kommt es gelegentlich zu atypischen Verschleißerscheinungen, die auf das Entstehen einer Neuhärtezone an der Werkstückoberfläche beim Bohren zurückgeführt werden. Grundsätzlich sind Randzonenveränderungen eine Folge der mechanischen und thermischen Beanspruchung bei der Bearbeitung. Beim Eindringen des Schneidkeils kommt es zu Kornverzerrungen, welche die Werkstückhärte bis in eine Tiefe von 40 bis 80 µm erhöhen können. Überdies wird die Randzone des Werkstücks durch den Bearbeitungsvorgang und den Spantransport erhitzt und durch den Kühlschmierstoff bzw. die so genannte Selbstabschreckung im Anschluss sehr schnell abgekühlt. So kann es in Abhängigkeit der Randbedingungen zu Gefügeänderungen mit härtesteigernder (Sekundärabschreckung) oder härtemindernder (Anlasseffekte) Wirkung kommen. Nicht zuletzt beeinflussen beide Beanspruchungsarten auch das Ausmaß der Eigenspannungen in der Werkstückoberfläche. In dieser Arbeit werden die beim Kernlochbohren erzeugten Randzonenveränderungen sowie die Standzeit von Folgebearbeitungswerkzeugen, wie Gewindebohrern und Gewindeformern, und deren Abhängigkeit vom Verschleißzustand des Kernlochbohrers untersucht. Weiterhin werden mit Hilfe einer Energiebilanz die Anteile herausgefiltert, die primär die Eigenschaften der Bohrungsrandzone beeinflussen. Dies geschieht mit Hilfe einer mathematischen Modellierung des Bohrprozesses, in der die Einflüsse der Schneidkantengeometrie, der Schneidkantenverrundung, der Schneidkantenfase sowie des Freiflächenverschleißes berücksichtigt werden.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing.

This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Fabrication, microstructure and mechanical properties of high performance ferrite-bainite steels

Low cost ferrite and bainite(FB) steels offer the prospect of high ultimate tensile strength combined with high hole expansion ratio. The enhanced strain hardening and formabilityof FB steels were primarily associated with the fine ferrite matrix, the low residual stresses and dislocation densityand compatible deformation between both phases.This overview describes the various techniques to produce FB steels, and comparestheresulting microstructure, tensile propertiesand tretchflangeabilitywith conventional HSLA and DP steels.A new generation of ultrafine ferrite and nano-scalebainiteautomotive steelsisunder development forthe futuredemands of extremely high strength and ductilitythroughthe fabricationtechnologiesinvolvingphase transformationsandplastic deformation.

Effect of roller leveling on the bending behaviour of aged steel strip

The common grades of steel used in roll forming are: hot rolled carbon steel, high strength low alloy and recovery annealed cold rolled sheet. These steels are prone to ageing and are often skin passed and/or roller leveled to eliminate ageing as it can lead to problems in forming. In roll forming, shape defects such as bow, twist and camber are considered to be related to very small plastic strains in the longitudinal direction and hence knowledge of the material properties in the elastic plastic transition range is necessary if the process is to be modelled accurately. Previous studies with aluminium have indicated that skin pass rolling can lead to residual stresses in the strip. In this work, the study was extended to aged carbon steel and to the effect of roller leveling on both aged material and strip that had been given a light cold rolling to simulate a skin pass treatment. The results suggest that roller leveling reduced the magnitude of residual stresses resulting from skin pass rolling.

The significant differences observed between tensile and bending test results, at and near, the elastic plastic transition reinforces the need to consider bending properties when assessing the effect of prior processing on strip for roll forming.

Using the solid-shell element to model the roll forming of large radii profiles

Roll forming is an incremental bending process for forming metal sheet, strip or coiled stock. Although Finite Element Analysis (FEA) is a standard tool for metal forming simulation, it is only now being increasingly used for the analysis of the roll forming process. This is because of the excessive computational time due to the long strip length and the multiple numbers of stands that have to be modelled. Typically a single solid element is used through the thickness of the sheet for roll forming simulations. Recent investigations have shown that residual stresses introduced during steel processing may affect the roll forming process and therefore need to be included in roll forming simulations. These residual stresses vary in intensity through the thickness and this cannot be accounted for by using only one solid element through the material thickness, in this work a solid-shell element with an arbitrary number of integration points has been used to simulate the roll forming process. The system modelled is that of roll forming a V-channel with dual phase DP780 sheet steel. In addition, the influence of other modelling parameters, such as friction, on CPU time is further investigated. The numerical results are compared to experimental data and a good correlation has been observed. Additionally the numerical results show that the CPU time is reduced in the model without friction and that considering friction does not have a significant effect on springback prediction in the numerical analysis of the roll forming process.