This paper presents the methodology and findings of a novel piece of research with the purpose of understanding and mitigating distortion caused by the combined processes of additive manufacturing (AM) and post machining to final specifications. The research work started with the AM building of a stainless steel 316L industrial impeller that was then machined by removing around 0.5mm from certain surfaces of the impeller's blades and hub. Distortion and residual stresses were experimentally measured. The manufacture of the impeller by AM and then machining was numerically simulated by applying the finite element (FE) method. Distortion and residual stresses were simulated and validated. The FE distortion was then used in a numerical procedure to reverse distortion directions in order to produce a new impeller with mitigated distortion. The results have shown that distortions in the new impeller, on average, have reduced to less than 50% of the original non-compensated values.
Earing and thinning are often the major manufacturing problems occur during deep drawing processes. Thinning occurs when a section of a part undergoes localised deformation, and earing is the formation of wavy edges at the open end of a drawn part that must be trimmed at final stage leading to higher manufacturing costs. The anisotropic mechanical behavior of the initial sheet metal is the predominant source of thinning and earing problems. This work aims to establish a relationship between the properties of a sheet blank and thinning and earing issues during deep drawing by studying the evolution of crystallographic texture throughout the sheet forming process using crystal plasticity simulation modelling and experimental measurements. Firstly, to understand the impact of individual texture components on the mechanical properties of the material, Lankford coefficients for FCC crystal structure during uni-axial tensile loading were analysed using Visco-Plastic Self Consistent (VPSC) model. Subsequently, Finite Element (FE) analyses were carried out to study the effect of initial state of the material on earing and thinning issues occurred during deep drawing. It was observed that the existing Cube and Goss texture components evolved during annealing heat treatments were responsible for the generation of troughs along 45° to the rolling direction (RD) and peaks along the transverse direction (TD), respectively. Optical 3D scanning of a manufactured part confirmed that earing is less prominent in the case of as-rolled and shear-formed condition due to weakening of Cube and Goss texture components. Furthermore, a combination of FE simulation and the VPSC model has been used to simulate texture evolution during a standard earing cupping test at various points of interest. The results of texture evolution simulations were compared to those measured experimentally by electron backscatter diffraction (EBSD), and a good qualitative agreement is achieved
The determination of residual stress in engineering materials with large grains is a challenge when it comes to using diffraction techniques. Not only are the accuracies of the residual stresses themselves important but also the accurate evaluation of their uncertainties. An austenitic steel three-pass slot weld (NeT- TG4) with varying grain size high-lights the potential problems with the data evaluation when grain size is not taken into account whilst measuring strain. Neutron diffraction results are compared with each other (with combinations of slit and radial oscillating collimator beam defining optics) and with high energy synchrotron radiation results with a spiral slit gauge volume defining system. The impact of the grain size on the determination of residual stresses and their associated uncertainties when using diffraction techniques in engineering components is emphasized and discussed. A simple model to estimate the extra random uncertainty contribution due to the so-called grain size statistics is applied and verified. The benefit of continuous or stepwise oscillation to increase the number of detected grains on the detector is discussed together with how to optimize the time of a measurement. From the data obtained, best practice guidelines will be suggested on dealing with large grains when determining strain and stress with neutron diffraction
Mechanical properties of a REX734 austenitic stainless steel were examined through compression testing over a wide range of temperatures (1173 K to 1373 K (900 °C to 1100 °C)) and strain rates (0.1 to 40 s−1) that cover deformation conditions encountered in different metalworking processes. The evolution of microstructure was studied using electron microscopy combined with electron backscatter diffraction and energy-dispersive spectroscopy. Partially recrystallized microstructures were obtained after compression testing at 1173 K (900 °C), while after deformation at 1273 K and 1373 K (1000 °C and 1100 °C), the material was fully recrystallized almost in all examined cases. The role of dynamic and metadynamic restoration processes in the formation of final microstructure was investigated. Σ3 twin boundaries lost their twin character and transformed into general high-angle grain boundaries as a result of deformation, while during recrystallization new Σ3 twin boundaries formed. The evolution of precipitates during compression testing and their role in the recrystallization process was also discussed.
The hydraulic bulge test represents an effective experimental method to characterise sheet metals since the equivalent strains before failure are much larger than those measured during tensile testing and there is nearly no frictional effect on the results. Recently this test has been proposed not only for extracting data concerning the equi-biaxial strain condition, but to determine the forming limit diagram (FLD) in the range of positive minor strains. In the proposed methodology, different strain paths can be obtained by merely using a test blank having two holes with a suitable geometry and position to be tested, without the need of dies with elliptical apertures. However, a carrier sheet is necessary, thus implying results may be affected by friction effects. This paper proposes a new methodology for the determination of the right side of the Forming Limit Curve (FLC), based on the adoption of local heat treatments aimed at determining different strain paths on the blank to be tested while using the classical circular die for bulge tests. In particular, the formability of the alloy AA5754-H32 was investigated; 3D Finite Element simulations were conducted setting different laser strategies and monitoring the resulting strain path. Results revealed that the proposed methodology supports obtaining many additional points in the right side of the FLC, thus being effective and friction free.
Flow forming is a near net shape process for manufacturing of dimensionally accurate hollow components such as shaft in gas turbines, that is currently at its development stage for aerospace industry. The process has several advantages such as reducing material wastage, extremely fast manufacturing time, and eliminating extra manufacturing processes such as machining. Due to the nature of this complicated cold deformation process, significant magnitude of residual stress is introduced into the component. Understanding the magnitude and distribution of residual stress is essential to tailor the flow forming process to achieve parts within dimensional tolerances and desired mechanical properties. The present research is aiming to explore the generation and evolution of residual stress at various stages of flow forming process in a tubular component made from martensitic 15Cr-5Ni stainless steel, using different techniques of neutron scattering, x-ray diffraction (XRD) and hole-drilling based on electronic speckle pattern interferometry (ESPI).Residual stress measurements were carried out in preformed and flow formed components at surface, near-surface and in the bulk of components using XRD, ESPI based hole-drilling and neutron diffraction techniques. These measurements were conducted at different levels of reduction in the thickness of the original part (i.e. after 20% and 40%), by applying identical forming parameters for all samples. The XRD results show significant change in hoop and axial residual stress levels with a reduction in the wall thickness. This is more pronounced for the axial component where the average stress switches from relatively high tensile (~ 450MPa) in the original part to significant compressive stress (~ -600MPa) in the formed part, after 20% of reduction. The bulk residual stress components measured in the middle of thickness of the parts, using neutron scattering, show a general increase in the magnitude of residual stress by higher level of deformation (i.e. reduction in the wall thickness). The measured bulk stress components through the thickness were tuned to tensile after reducing the wall thickness by 40%. The results of XRD and neutron diffraction stress measurements suggest that the residual stress along the length of the samples (i.e. axial direction) is consistent with ±800 MPa and
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