Residual Stress Prediction for Part Distortion Modeling

Document Number: 2006-01-3171

Date Published: September 2006

Author(s):
Andy Grevstad - Third Wave Systems

Abstract:
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.

File Size: 418K
Product Status: In Stock

See other papers presented at Aerospace Manufacturing and Automated Fastening Conference and Exhibition, September 2006, Toulouse, FRANC, Session: Advanced Forming, Machining and Modeling Part 2 of 2

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