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Prediciting residual stresses and hardness of a critical component using a combination of numerical and empirical methods
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2008 (English)In: Steel Research International Journal, ISSN 1611-3683, no Sp. Iss. 2, 812-819 p.Article in journal (Refereed) Published
Abstract [en]

This paper describes the experiences gained when using numerical and empirical methods in order to predict the accumulated surface characteristics for a safety component after several forging steps, controlled cooling and blasting. The forging steps were simulated in a sequence using one Finite Element (FE) code. The output forging mesh was used as input to the cooling simulation but was too coarse in order to reflect surface characteristics. The decarburisation effect during cooling that may influence the surface characteristics was not included in the cooling model. An attempt to create a parametric model of the blasting machine with output residual stresses and hardness as a function of input residual stresses, hardness and process parameters indicated the need of further investigation concerning the physical phenomena during blasting in the machine. A new method was developed for analysing the influence of the blasted surface texture on the stress intensity. The measured residual stresses and hardness span caused by variations in the blasting process were successfully used together with the stress intensity factor as input to a fatigue strength analysis. In order to establish a seamless chain of models through the manufacturing sequence further development concerning cooling and blasting models is required.

Place, publisher, year, edition, pages
2008. no Sp. Iss. 2, 812-819 p.
Keyword [en]
Sequential simulation, manufacturing chain, fatigue properties
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:kth:diva-25904ISI: 000267944700116OAI: oai:DiVA.org:kth-25904DiVA: diva2:360702
Note
QC 20101104. 12th International Conference on Metal Forming Cracow, POLAND, SEP 21-24, 2008 Available from: 2010-11-04 Created: 2010-11-04 Last updated: 2015-10-16Bibliographically approved
In thesis
1. Simulation of manufacturing sequences for verification of product properties
Open this publication in new window or tab >>Simulation of manufacturing sequences for verification of product properties
2009 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The manufacturing sequence may to a large extent influence properties like residual stresses and hardness and, as a consequence, the fatigue life and shape accuracy of a component. By simulating the manufacturing sequence and extract important accumulated data, the possibilities of early analysis of a design concept of a component and optimisation of the complete manufacturing sequence may increase. An established methodology has the potential to reduce physical testing, increase the process knowledge and reduce product development time and costs. This thesis suggests principles for simulating manufacturing sequences for forged and sheet metal-formed components.

It is possible to establish virtual manufacturing sequences and connect different commercial simulation softwares into a chain with support from methods for data communication and in process modelling. However, the data communication has pitfalls and also material data, process data and material models for single processes may be insufficient in order to conduct a quantitative analysis of the accumulated properties. Thus, a thorough validation of the sequential simulation results should be performed. Further, engineering simplifications of the sequence are recommended and e.g. a combination of numerical and empirical methods may be preferable in order to predict accumulated results with high accuracy. Future development concerning standards for data communication as well as meshing, mapping and modelling technique is recommended in order to improve the quality of the accumulated results. Finally, methods for integration of sequential simulation in the overall component design process, including conventional Computer Aided Design (CAD) and Finite Element Analysis (FEA), should be developed. The main advantage of sequential simulation may be conceptual studies of process and material parameter variations and their influence on the final product properties.

Paper I describes how to select the most critical process parameters in a manufacturing sequence. Paper II describes how to establish a sequence using a combination of numerical and empirical methods and paper III describes state of the art concerning shot peening simulation.

Place, publisher, year, edition, pages
Stockholm: KTH, 2009. 35 p.
Series
Trita-IIP, ISSN 1650-1888 ; 2009:02
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-10217 (URN)
Presentation
2009-03-27, Brinellsalen M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Supervisors
Available from: 2009-04-15 Created: 2009-04-15 Last updated: 2010-11-04Bibliographically approved
2. Principles for modelling of manufacturing sequences
Open this publication in new window or tab >>Principles for modelling of manufacturing sequences
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The manufacturing sequence influence, to a large extent, component properties like fatigue life, shape accuracy and manufacturability. By simulating the manufacturing sequence, using numerical or empirical models, and extracting important accumulated data, like residual stress, hardness and shape, the possibilities of early analysis of a design concept and the associated manufacturing sequence will increase. An established methodology has the potential of reducing physical testing and the time and costs of product design and process planning.

This thesis proposes an algorithm to be used for setting up a framework of interconnected process step models. With support from the algorithm, it is possible to extract a virtual simulation sequence from a physical manufacturing sequence. Thereby, you can replicate the aggregated effects of process steps on part key features and manufacturing features. The algorithm will serve as a tool in process planning when establishing virtual manufacturing sequences. The virtual sequences should be used for virtual prediction of component properties, optimization of process parameters and evaluation of the effects of replacing, removing or adding process steps to a manufacturing sequence

The algorithm is based on stepwise upstream selection of process steps, definition of interconnected models and selection of interconnected datasets using breadth first search. The algorithm completes existing procedures for data mapping and exchange of data between models into an overall approach for establishing virtual manufacturing sequences. Other scientific contributions are methods for modelling of deep rolling and blasting, a model material for validation of rolling and forging simulation and principles for integration of process simulation with CAD/CAM.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. iii, 33 p.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-175476 (URN)978-91-7595-731-9 (ISBN)
Public defence
2015-11-06, Brinellsal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20151016

Available from: 2015-10-16 Created: 2015-10-15 Last updated: 2015-12-30Bibliographically approved

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