Thermal-Mechanical Efect and Removal Mechanism of Ti-6Al-4V During Laser-Assisted Grinding

The low density and high corrosion resistance of titanium alloy make it a material with various applications in the aerospace industry. However, because of its high specifc strength and poor thermal conductivity, there are problems such as high cutting force, poor surface integrity, and high cutting temperature during conventional machining. As an advanced processing method with high efciency and low damage, laser-assisted machining can improve the machinability of titanium alloy. In this study, a picosecond pulse laser-assisted scratching (PPLAS) method considering both the temperature-dependent material properties and ultrashort pulse laser’s characteristics is frst proposed. Then, the efects of laser power, scratching depth, and scratching speed on the distribution of stress and temperature feld are investigated by simulation. Next, PPLAS experiments are conducted to verify the correctness of the simulation and reveal the removal behavior at various combinations of laser power and scratching depths. Finally, combined with simulated and experimental results, the removal mechanism under the two machining methods is illustrated. Compared with conventional scratching (CS), the tangential grinding force is reduced by more than 60% and the material removal degree is up to 0.948 during PPLAS, while the material removal is still primarily in the form of plastic removal. Grinding debris in CS takes the form of stacked fakes with a “fsh scale” surface, whereas it takes the form of broken serrations in PPLAS. This research can provide important guidance for titanium alloy grinding with high surface quality and low surface damage.

Fatigue behaviour of coke drum materials under thermal-mechanical cyclic loading

Coke drums are vertical pressure vessels used in the delayed coking process in petroleum refineries. Significant temperature variation during the delayed coking process causes damage in cracking. There were some studies on coke drums in the form of bulging and the fatigue life estimation for the coke drums, but most of them were based on strain-fatigue life curves at constant temperatures, which do not consider simultaneous cyclic temperature and mechanical loading conditions. In this study, a fatigue testing system is successfully devel- oped to allow performing thermal-mechanical fatigue （TMF） test similar to the coke drum loading condition. Two commonly used base and one clad materials of coke drums are then experimentally investigated. In addition, a comparative study between isothermal and TMF lives of these materials is conducted. The experimental findings lead to better understanding of the damage mechanisms occurring in coke drums and more accurate prediction of fatigue life of coke drum materials.

Numerical simulation of a sheet metal extrusion process by using thermal-mechanical coupling EAS FEM

The thermal-mechanical coupling finite element method(FEM)was usedto simulate a non-isothermal sheet metal extrusion process. On thebasis of the finite plasticity consistent with multiplicativedecomposition of the deformation gradient, the enhanced as- sumedstrain(EAS)FEM was applied to carry out the numerical simulation. Inorder to make the computation reliable ad avoid hour- glass mode inthe EAS element under large compressive strains, an alterative formof the original enhanced deformation gradient was employed. Inaddition, reduced factors were used in the computation of the elementlocal internal parameters and the enhanced part of elementalstiffness.

EFFECTS OF STRAIN RATIO ON THERMAL-MECHANICAL CYCLIC STRESS-STRAIN RESPONSE AND FATIGUE LIFE IN DS SUPERALLOY DZ125

The effects of strain ratio on thermal-mechanical cyclic stress-strain response and fatigue life in DS superalloy DZ125 have been studied by performing tests at various strain ratio experiments, under strain-controlled and temperature cycling from 550 to 1000℃. It is shown that thermal-mechanical cyclic stress-strain response behavior not only depend on magnitude of strain, and temperature-loading phase angle, but also strain ratio. Fatigue life at strain ratio Rε=-0.3 is longer than that of strain ratio Rε=-1.0, under in-phase thermal-mechanical loading. However, Fatigue life at strain ratio Rε=-0.3 is shorter than that of strain ratio Rε=-1.0, under out-of-phase thermal-mechanical loading. The thermal-mechanical fatigue (TMF) damage model was discussed. Results of fractography show that fatigue, creep and oxidation damage always occur during TMF. The main damage mode depends on loading wave, strain ratio and magnitude of strain.

First Cycle Effect of Polycrystalline CuZnAl Shape Memory Alloy during Thermal-Mechanical Cycling

The thermal-mechanical (T-M) cycles at constant strain of a polycrystalline CuZnAl alloy have been studied in the. present work. In-situ optical microscopic observations have been made to reveal the features of the phase transitions during T-M cycling. The variation of stress-temperature (S-T) curves and electrical resistance-temperature (R-T) curves accompanying with T-M cycling have been measured by tensile test and electrical resistance measurements. It has been found that the polycrystalline CuZnAl alloy shows apparent morphology changes and properties variations in the first cycle during T-M cycling which is called the first cycle effect in the present work. The stable transformation procedure in the T-M cycle is: martensiteparent phase +residual acicular martensite. This residual martensite possesses the character of stress-induced martensite.

ANALYSIS OF SHAKEDOWN OF FG BREE PLATE SUBJECTED TO COUPLED THERMAL-MECHANICAL LOADINGS

The static and kinematic shakedown of a functionally graded （FG） Bree plate is analyzed. The plate is subjected to coupled constant mechanical load and cyclically varying temperature. The material is assumed linearly elastic and nonlinear isotropic hardening with elastic modulus,yield strength and the thermal expansion coeffcient varying exponentially through the thickness of the plate. The boundaries between the shakedown area and the areas of elasticity,incremental collapse and reversed plasticity are determined,respectively. The shakedown of the counterpart made of homogeneous material with average material properties is also analyzed. The comparison between the results obtained in the two cases exhibits distinct qualitative and quantitative difference,indicating the importance of shakedown analysis for FG structures. Since FG structures are usually used in the cases where severe coupled cyclic thermal and mechanical loadings are applied,the approach developed and the results obtained are significant for the analysis and design of such kind of structures.

Analysis of thermal-mechanical coupled characteristics of vehicle twin-tube shock absorber

A comprehensive model that included mechanical dynamics of the shock absorber coupled with its thermal properties was proposed innovatively.Moreover a thermal-mechanical coupled model which reflected the closed-loop positive feedback system was established by using MATLAB/SIMULINK,and some curves of shock absorber temperature rising characteristic were obtained by simulation ＆computation under several operating modes and different parameters conditions.Research results show that：shock absorber design parameters,external excitations,and thermo-physical properties parameter,such as oil density have effect on the shock absorber temperature rising characteristic.However other thermo-physical properties parameters,such as oil specific heat,cylinder density,cylinder specific heat,and cylinder thermal conductivity,have no effect on it.The results may be used for studying reliability design of the shock absorber.

Thermal-Mechanical Coupled FE Analysis for Rotary Shaft Seals

The aim of this paper is to model the steady-state condition of a rotary shaft seal (RSS) system. For this, an iterative thermal-mechanical algorithm was developed based on incremental finite element analyzes. The behavior of the seal’s rubber material was taken into account by a large-strain viscoelastic, so called generalized Maxwell model, based on Dynamic Mechanical Thermal Analyses (DMTA) and tensile measurements. The pre-loaded garter spring was modelled with a bilinear material model and the shaft was assumed to be linear elastic. The density, coefficient of thermal expansion and the thermal conductance of the materials were taken into consideration during simulation. The friction between the rotary shaft seal and the shaft was simplified and modelled as a constant parameter. The iterative algorithm was evaluated at two different times, right after assembly and 1 h after assembly, so that rubber material’s stress relaxation effects are also incorporated. The results show good correlation with the literature data, which state that the permissible temperature for NBR70 (nitrile butadiene rubber) material contacting with ~80 mm shaft diameter, rotating at 2600/min is 100°C. The results show 107°C and 104°C for the two iterations. The effect of friction induced temperature, changes the width of the contact area between the seal and the shaft, and significantly reduces the contact pressure.

Thermal-mechanical coupled effect on fracture mechanism and plastic characteristics of sandstone

Scanning electronic microscopy (SEM) was employed to investigate fractographs of sandstone in mine roof strata under thermal-mechanical coupled effect. Based on the evolution of sandstone surface morphology in the failure process and frac- tography, the fracture mechanism was studied and classified under meso and mi- cro scales, respectively. The differences between fractographs under different tem- peratures were examined in detail. Under high temperature, fatigue fracture and plastic deformation occurred in the fracture surface. Therefore, the temperature was manifested by these phenomena to influence strongly on micro failure mechanism of sandstone. In addition, the failure mechanism would transit from brittle failure mechanism at low temperature to coupled brittle-ductile failure mechanism at high temperature. The variation of sandstone strength under differ- ent temperature can be attributed to the occurrence of plastic deformation, fatigue fracture, and microcracking. The fatigue striations in the fracture surfaces under high temperature may be interpreted as micro fold. And the coupled effect of tem- perature and tensile stress may be another formation mechanism of micro fold in geology.

Fluid-Thermal-Mechanical Coupled Analysis and Optimized Design of Printed Circuit Heat Exchanger with Airfoil Fins of S-CO_(2) Brayton Cycle

Printed Circuit Heat Exchanger(PCHE) with high-efficiency and compact structure has great application prospect in the supercritical carbon dioxide(S-CO_(2)) power systems for the next generation of high-temperature concentrated solar and advanced nuclear energy. However, the high operating temperature and pressure require PCHE to maintain good heat transfer performance, as well as reliable mechanical performance at the same time. It is necessary to carry out the fluid-thermal-mechanical coupled analysis of PCHE for the safe and efficient operation of the S-CO_(2) cycle. In this paper, a three-dimensional fluid-structure coupled numerical model was established to study the fluid-thermal-mechanical coupled characteristics of PCHE under different airfoil fin arrangements. The stress distribution of the single airfoil fin was studied, and a better airfoil arrangement that comprehensively considers heat transfer characteristics and stress distribution was obtained. Aiming at the high stress caused by the stress concentration at both ends of the airfoil fin, an optimized configuration combining straight channel and airfoil channel was proposed. The results show that the difference between the flow and heat transfer performance of the two optimized structures and the reference structure is only within 1.5%, but the maximum stresses of the two optimized structures are respectively reduced by 69.4% and 70.0% compared with that of the reference structure, which significantly reduces the stress intensity of PCHE. The result provides a new method to develop the airfoil PCHE with uniform stress distribution and good thermo-hydraulic performance.

Optimized Design for a Combined Die with Two Stress Rings in Cold Forging Considering Thermal-Mechanical Effects

Stress analysis and optimization of combined die structure with two stress rings were performed.Using thermoelastic deformation,the contact pressure at the interfaces between layers was calculated.Then,theoretical expressions of stress distribution for the combined die were derived.The thermal-mechanical effect under working conditions was considered.To verify the theoretical expressions,simulation work was performed.Optimization of die design was carried out by defining radius ratio and shrink fit coefficient as optimization variables.The objective was to minimize the effective circumferential stress at the inner surface of the die insert,under the constraint that the maximum equivalent stress values of die insert and stress rings did not exceed their respective yield stresses.The Kriging model was used to describe the influence of shrink fit and die dimensions on the objective function and the maximum equivalent stress.Using a genetic algorithm,optimum parameters were found with a minimum circumferential stress of 442.9 MPa under a working stress of 1800 MPa.Further analysis of five selected optimal results was carried out,and the specific design parameters of these combined dies are different under the same level of circumferential stress,and the combined die is overdesigned if the thermal effect is ignored.

An Innovative Finite Element Geometric Modeling of Single-Layer Multi-Bead WAAMed Part

Finite element (FE) coupled thermal-mechanical analysis is widely used to predict the deformation and residualstress of wire arc additive manufacturing (WAAM) parts. In this study, an innovative single-layermulti-bead profilegeometric modeling method through the isosceles trapezoid function is proposed to build the FE model of theWAAMprocess. Firstly, a straight-line model for overlapping beads based on the parabola function was establishedto calculate the optimal center distance. Then, the isosceles trapezoid-based profile was employed to replace theparabola profiles of the parabola-based overlapping model to establish an innovative isosceles trapezoid-basedmulti-bead overlapping geometric model. The rationality of the isosceles trapezoid-based overlapping model wasconfirmed by comparing the geometric deviation and the heat dissipation performance index of the two overlappingmodels. In addition, the FE-coupled thermal-mechanical analysis, as well as a comparative experiment of thesingle-layer eight-bead deposition process show that the simulation results of the above two models agree with theexperimental results. At the same time, the proposed isosceles trapezoid-based overlappingmodels are all straightlineprofiles, which can be divided into high-quality FE elements. It can improve the modeling efficiency andshorten the simulation calculation time. The innovative modeling method proposed in this study can provide anefficient and high-precision geometricmodelingmethod forWAAMpart FE coupled thermal-mechanical analysis.

Dynamic explicit FE modeling of hot ring rolling process

A new FE modeling method of hot ring rolling was presented by solving key technologies such as contact and heat boundary conditions,motion control over guide rolls,and mass scaling.The method has the following features:1)the elastic-plastic dynamic explicit approach instead of the static implicit approach is adopted to solve the process so as to greatly improve computational efficiency without sacrificing computational accuracy;2)the coupled thermal-mechanical effect is considered as opposed to the conventional isothermal assumption,which is more practical;3)in contrast to the simplified 2D or local 3D ring model,the full 3D ring is modeled to simulate the process.Based on the FE modeling method,two cases of hot plain ring rolling are simulated in the FEA software ABAQUS/Explicit.The simulation results are compared with the experimental measurements and the good agreement between them is observed regarding the material flow and the temperature distribution of the ring.

一种用于光机热集成分析的新方法——干涉图插值法

Zernike多项式是光机热集成分析中实现光、机、热各分析软件之间数据传递的重要工具。许多光学元件表面形状并不满足Zernike多项式的正交性条件,使有限元分析不能精确拟合光学元件表面变形及变形产生的各项像差。讨论影响Zernike正交性的几个因素,详细介绍将有限元分析得到的光学表面变形数据导入光学分析软件的一种新方法——干涉图插值法。该方法避开Zernike多项式拟合,在去除镜面刚体位移后将镜面畸变精确地表示成干涉图数据,直接生成数据接口。

GURTIN-TYPE VARIATIONAL PRINCIPLES FOR DYNAMICS OF A NON-LOCAL THERMAL EQUILIBRIUM SATURATED POROUS MEDIUM

Based on the porous media theory and by taking into account the efects of the pore fuid viscidity, energy exchanges due to the additional thermal conduction and convection between solid and fuid phases, a mathematical model for the dynamic-thermo-hydro-mechanical coupling of a non-local thermal equilibrium fuid-saturated porous medium, in which the two constituents are assumed to be incompressible and immiscible, is established under the assumption of small de- formation of the solid phase, small velocity of the fuid phase and small temperature changes of the two constituents. The mathematical model of a local thermal equilibrium fuid-saturated porous medium can be obtained directly from the above one. Several Gurtin-type variational principles, especially Hu-Washizu type variational principles, for the initial boundary value problems of dy- namic and quasi-static responses are presented. It should be pointed out that these variational principles can be degenerated easily into the case of isothermal incompressible fuid-saturated elastic porous media, which have been discussed previously.

BREAKAGE MECHANISM OF TUNGSTEN BASED ALLOY BLOCK FOR ELECTRO-HEAT UPSETTING

The breakage mechanism of W-Ni-Fe alloy in the process of electro-heat upsetting studied both theoretically and experimetnally, and also the behaviors of crack formation and propagation were analysed. Alloy suffers from corrosion and thermal-mechanical fatigue mutual function. Simultaneously, the practical ways to improve the anvil life was discussed.

FINITE ELEMENT ANALYSIS OF THERMOELASTIC BEHAVIOR OF PIEZOELECTRIC STRUCTURES UNDER FINITE DEFORMATION

It is noted that the behavior of most piezoelectric materials is temperaturedependent and such piezo-thermo-elastic coupling phenomenon has become even more pronounced in thecase of finite deformation. On the other hand, for the purpose of precise shape and vibrationcontrol of piezoelectric smart structures, their deformation under external excitation must beideally modeled. This demands a thorough study of the coupled piezo-thermo-elastic response underfinite deformation. In this study, the governing equations of piezoelectric structures areformulated through the theory of virtual displacement principle and a finite element method isdeveloped. It should be emphasized that in the finite element method the fully coupledpiezo-thermo-elastic behavior and the geometric non-linearity are considered. The method developedis then applied to simulate the dynamic and steady response of a clamped plate to heat flux actingon one side of the plate to mimic the behavior of a battery plate of satellite irradiated under thesun. The results obtained are compared against classical solutions, whereby the thermal conductivityis assumed to be independent of deformation. It is found that the full-coupled theory predicts lesstransient response of the temperature compared to the classic analysis. In the steady state limit,the predicted temperature distribution within the plate for small heat flux is almost the same forboth analyses. However, it is noted that increasing the heat flux will increase the deviationbetween the predictions of the temperature distribution by the full coupled theory and by theclassic analysis. It is concluded from the present study that, in order to precisely predict thedeformation of smart structures, the piezo-thermo-elastic coupling, geometric non-linearity and thedeformation dependent thermal conductivity should be taken into account.

Microcrack-and microvoid-related impact damage and ignition responses for HMX-based polymer-bonded explosives at high temperature

Investigating the damage and ignition behaviors of polymer-bonded explosive(PBX) under a coupled impact and high-temperature loading condition is required for the safe use of charged PBXs. An improved combined microcrack and microvoid model(CMM) was developed for better describing the thermal effects of deformation, damage, and ignition responses of PBXs. The main features of the model under typical dynamic loadings(i.e. uniaxial tension and compression, and lateral confinement) at different initial temperature were first studied. And then the effects of temperature on impact-shear sensitivity of HMX-based PBXs were investigated. The results showed that the ignition threshold velocity of shear-crack hotspots exhibits an increase from 260 to 270 to 315-325 m/s when initial temperature increases from 301 to 348 K;and then the threshold velocity decreases to 290-300 m/s with the initial temperature continually increasing to 378 K. The predicted ignition threshold velocity level of the explosives under coupled impact and high temperature loading conditions were consistent with the experimental data.

Dynamic simulation of resistance spot welding of zinc-coated steels

A model was developed to simulate the temperature distribution and nugget formation during resistance spot welding （ RS1V） of zinc-coated steels. It employs a coupled thermal-electrical-mechanical analysis simulating the dynamic RSW process. Temperature-dependent thermal-electrical-mechanical material properties were considered including contact-resistance. The contact area was determined from a coupled thermal-mechanical analysis. A layer of transition elements was used to represent the change of contact area by killing or activating elements. The heat generation and temperature field were computed in a coupled thermal-electrical model. All these analyses were solved using the commercial finite element method （FEM） based on ANSYS code, and some advanced functions were used by writing a paragraph of codes by the authors. Compared with the results from only coupled thermal-electrical model in which contact area was uniform during the whole process, the result matches better to the experimental results.