Characterization of Residual Stresses in Conventional Forming and Hydroforming of Tailor Welded Blanks

Kumar, Amit; Digavalli, Ravi Kumar; Gautam, Vijay; Hariharan, K.

doi:10.1007/s11665-022-07020-y

Cited by 3 publications

(2 citation statements)

References 30 publications

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“…The prediction of the residual stresses is also very important for metal forming processes. However, the majority of authors, e.g., [ 39 , 40 , 41 , 42 , 43 , 44 , 45 ], studied this phenomenon as only welding problems or metal forming problems, thus separately and not as two consecutive steps. Some authors [ 46 , 47 , 48 ] dealt with the determination of residual stress in formed members and predicted results were compared with the experiments (sectioning, hole drilling method and X-ray diffraction).…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Analysis of the Residual Stresses in Seamed Pipe in Dependence on Welding and Metal Forming

et al. 2023

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Concerning the increasingly widespread utilization of the finite element method (FEM), the concept of the so-called virtual factory is also gaining ground, and not only in the engineering industry. This approach does not use numerical simulations of individual production technologies separately but treats the entire production process as a chain of interrelated technologies. Thus, the output data from one technology is taken as input data for the following technology. The resulting thermal and mechanical effects are then not only dealt with within one technology but always comprehensively within the production process. In the consideration of the loading and subsequent service lives of manufactured components, values of residual stresses are one of the very important characteristics. For these reasons, this paper deals with the effect of residual stresses’ magnitude and distribution during the formation and the final springback of the seamed pipe end section with and without respect to the influence of the preceding welding. The resulting residual stress values from numerical simulations are subsequently compared with the actual values of residual stresses experimentally measured using X-ray diffraction.

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Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Analysis of the Residual Stresses in Seamed Pipe in Dependence on Welding and Metal Forming

et al. 2023

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“…Moreover, for the residual strain after plastic deformation, researchers in the field of plastic forming paid more attention to the variation of thickness distribution of sheet metal, but the thickness distribution was mainly dominated by plastic strain under loading process, and elastic strain (< 0.02) often could be ignored [29,30]. Notably, due to the strain hardening effect, non-uniform distribution of residual strain meant the non-uniform distribution of microhardness at the workpiece surface, and the microhardness was an important index in milling.…”

mentioning

confidence: 99%

Gradient thickness-dependent distribution of residual stress and springback of thin-walled TC4 titanium alloy sheet with variable thickness in collaborative manufacturing process of pre-plastic forming and milling

SHU,

REN,

ZHANG

et al. 2024

Preprint

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Thin-walled sheet components with variable thickness and complex curved surface are expanding considerably in the advanced manufacturing field of aerospace industry due to its aerodynamic shape and light-weight characteristics, and collaborative manufacturing method of pre-plastic forming and milling was used to solve the problems of low rough milling efficiency and large milling difficult of such components. However, the structural characteristics of thin-walled and variable thickness brought the problems of residual stress and springback after pre-plastic forming, which impacted the milling quality and increased milling allowance in subsequent milling. In this work, based on three-point bending tests of thin-walled TC4 titanium alloy sheets with different ratio of thickness variation (ζ) and its Finite Element Analyze (FEA), gradient thickness-dependent distribution of residual stress and springback after pre-plastic forming was systematically studied. The results showed that with the ζ increasing from 1 to 6, difference of residual stress (Δσres) between both sides increased from 0 to 356.81 MPa, difference of springback (ΔS) between both sides increased 0 to 0.23 mm, and Springback Angle (SA) increased from 11.02 ° to 11.88 °, which was due to the increasing of stress component along the breadth direction and the decreasing of strain component along the thickness direction, and specimen #5 (ζ = 3) had more uniform distribution of residual stress. In addition, through considering the decay of elastic modulus (E) after plastic deformation, absolute error of SA of specimen #6 (ζ = 6) was reduced from 1.98 ° to 0.95 °.

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Numerical investigation of controllable non-uniform deformation of tailor-welded blanks using heterogeneous pressure-carrying medium

Shu

Xiang

Wang

et al. 2023

Thin-Walled Structures

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Characterization of Residual Stresses in Conventional Forming and Hydroforming of Tailor Welded Blanks

Cited by 3 publications

References 30 publications

Experimental and Numerical Analysis of the Residual Stresses in Seamed Pipe in Dependence on Welding and Metal Forming

Experimental and Numerical Analysis of the Residual Stresses in Seamed Pipe in Dependence on Welding and Metal Forming

Gradient thickness-dependent distribution of residual stress and springback of thin-walled TC4 titanium alloy sheet with variable thickness in collaborative manufacturing process of pre-plastic forming and milling

Numerical investigation of controllable non-uniform deformation of tailor-welded blanks using heterogeneous pressure-carrying medium

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