Finite element simulation and experimental investigation of machining induced residual stresses in ultrasonic elliptical vibration-assisted turning

Ahmadpoor, Seyyed Sajjad; Khajehzadeh, Mohsen; Razfar, Mohammad Reza

doi:10.1080/10910344.2022.2129980

Cited by 4 publications

(2 citation statements)

References 21 publications

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“…The research results indicated that the residual compressive stress on the silicon wafer surface induced by ultrasonic vibration-assisted wire sawing was more significant than that caused by traditional wire sawing. Ahmadpoor et al [32] developed a three-dimensional finite element method to study the differences between ultrasonic-assisted turning and conventional turning. They proposed and prepared an elliptically vibrating tool, which was applied in ultrasonic-assisted turning.…”

Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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Ultrasonic vibration-assisted grinding (UVAG) technology has advantages in improving part surface integrity. Currently, the calculation of residual stresses in UVAG typically relies on commercial finite element software. However, because commercial finite element software is not specialized for residual stress calculations, the computational efficiency could be higher, and the accuracy could be better. This paper proposes a semi-analytical residual stress prediction model that considers the Influence of ultrasonic vibration. This paper introduces a semi-analytical residual stress prediction model that considers the impact of ultrasonic vibration. The model calculates the grinding mechanical and thermal stress fields separately using contact mechanics and finite difference methods. Based on Hertz's contact theory and Timoshenko's thermoelastic theory, a correlation model is provided for the association between mechanical and thermal loads with the internal stresses in the workpiece. Subsequently, the residual stress field is solved by considering the thermal-mechanical coupling effects in UVAG. Ultrasonic-assisted grinding experiments were conducted using 12Cr2Ni4A alloy steel as the object, and the maximum error between the predicted residual stresses by the model and the measured residual stresses was 10.5%.In addition, the detailed discussion on the Influence of grinding parameters on residual stress reveals that reducing the grinding wheel speed can significantly increase surface compressive residual stress. The paper's research shows that the residual stress distribution obtained by the new residual stress calculation model is correct, and the calculation efficiency is high, providing a new method for predicting residual stress in UVAG.

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Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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“…Generally, experimental techniques have many limitations, such as laboriousness, time-consumingness, a limited range of sizes and shapes that can be measured, as well as a lack of accuracy dependent on the skill of the operators as well as the capabilities of the machine. Therefore, the development of computational means in the second half of the 20th century led to the development of computational methods aimed at algorithmizing engineering tasks through differential methods, which include finite element methods and integral methods (Maroju and Pasam, 2019;Peng et al, 2021;Ahmadpoor et al, 2022). The paper (Elsheikh et al, 2021) provides a detailed review on residual stresses induced by turning on machined components.…”

Section: Introductionmentioning

confidence: 99%

Proposal for the identification of residual stresses after turning and hardening of bearing steel

Šafář,

Valíček,

Harničárová

et al. 2023

Front. Mater.

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Residual stresses are defined as the stresses that occur in the material without the application of an external load. Their occurrence is related to the technology of production and treatment of the material. This article proposes the identification of residual stresses in a steel material for bearing production, specifically 100Cr6 (1.3505) material. The identification consists in measuring the material by X-ray diffraction method, for which the Proto iXRD mobile diffractometer was chosen. The first measurement was carried out on turned bearing rings and a subsequent second measurement was carried out on the same rings after heat treatment, namely quenching and tempering. This article also proposes a measurement methodology for the bearing rings, where each ring is measured in 6 positions rotated 60° with respect to each other. The measurement results are compared with the individual manufacturing operations, i.e. turning and heat treatment. The results clearly show the expected increase in residual stresses after turning and subsequent decrease after heat treatment. The technological parameters of turning fundamentally influence the residual stresses and thus also affect the quality of the product in subsequent production operations.

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Calculation of residual stress in ultrasonic vibration assisted grinding considering thermal-mechanical coupling: a numerical-analytical hybrid prediction approach

Ye,

Wen,

Tang

et al. 2024

Mech Time-Depend Mater

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Finite element simulation and experimental investigation of machining induced residual stresses in ultrasonic elliptical vibration-assisted turning

Cited by 4 publications

References 21 publications

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Proposal for the identification of residual stresses after turning and hardening of bearing steel

Calculation of residual stress in ultrasonic vibration assisted grinding considering thermal-mechanical coupling: a numerical-analytical hybrid prediction approach

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