Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process
Laser cladding (LC) is an advantageous surface modification technique. However, in the case of a thin substrate or a large process area to substrate, large thermal distortions could be generated, which can affect the dimensional accuracy of machinery parts. A substrate fixation method in the manufac...
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The Japan Society of Mechanical Engineers
2024-11-01
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| Series: | Mechanical Engineering Journal |
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| Online Access: | https://www.jstage.jst.go.jp/article/mej/11/6/11_24-00251/_pdf/-char/en |
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| author | Taisei IZUMI Ayumu YANO Masayuki ARAI |
| author_facet | Taisei IZUMI Ayumu YANO Masayuki ARAI |
| author_sort | Taisei IZUMI |
| collection | DOAJ |
| description | Laser cladding (LC) is an advantageous surface modification technique. However, in the case of a thin substrate or a large process area to substrate, large thermal distortions could be generated, which can affect the dimensional accuracy of machinery parts. A substrate fixation method in the manufacturing process can mitigate thermal distortion. However, this fixation may induce residual tensile stress in the LC layer. Therefore, a simulation technique is required for scenarios with and without substrate fixation during laser cladding. In this study, models of a cantilevered plate (Cl) and a plate fixed at both ends (Fix) were developed. A 3D coupled thermo-mechanical analysis was performed using the element birth-death technique. Isotropic and kinematic hardening laws were also applied to the Cl and Fix models to compare the simulation results of thermal distortion and residual stress distribution. The Cl model with the isotropic hardening law achieved a higher simulation accuracy, while the model with the kinematic hardening law overestimated the thermal distortion. Conversely, the kinematic hardening law closely matched the experimental results in the Fix model. In addition, the comparison of normal stress–plastic strain diagrams revealed large compressive plastic strains repeatedly induced in the substrate regions below the interface in the Fix model due to substrate fixation during LC. The repeated plastic deformation induced the Bauschinger effect, which increased the simulation accuracy with the kinematic hardening law. These findings are crucial for accurately predicting residual stresses and thermal distortions in LC processes with substrate fixation. |
| format | Article |
| id | doaj-art-5eff797fc8ca4d5dabfed5d1d57e5cdc |
| institution | Kabale University |
| issn | 2187-9745 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | The Japan Society of Mechanical Engineers |
| record_format | Article |
| series | Mechanical Engineering Journal |
| spelling | doaj-art-5eff797fc8ca4d5dabfed5d1d57e5cdc2024-12-18T08:34:16ZengThe Japan Society of Mechanical EngineersMechanical Engineering Journal2187-97452024-11-0111624-0025124-0025110.1299/mej.24-00251mejEffect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding processTaisei IZUMI0Ayumu YANO1Masayuki ARAI2Thermal Spraying Technology R&D Laboratories, TOCALO Co., Ltd.Thermal Spraying Technology R&D Laboratories, TOCALO Co., Ltd.Department of Mechanical Engineering, Tokyo University of ScienceLaser cladding (LC) is an advantageous surface modification technique. However, in the case of a thin substrate or a large process area to substrate, large thermal distortions could be generated, which can affect the dimensional accuracy of machinery parts. A substrate fixation method in the manufacturing process can mitigate thermal distortion. However, this fixation may induce residual tensile stress in the LC layer. Therefore, a simulation technique is required for scenarios with and without substrate fixation during laser cladding. In this study, models of a cantilevered plate (Cl) and a plate fixed at both ends (Fix) were developed. A 3D coupled thermo-mechanical analysis was performed using the element birth-death technique. Isotropic and kinematic hardening laws were also applied to the Cl and Fix models to compare the simulation results of thermal distortion and residual stress distribution. The Cl model with the isotropic hardening law achieved a higher simulation accuracy, while the model with the kinematic hardening law overestimated the thermal distortion. Conversely, the kinematic hardening law closely matched the experimental results in the Fix model. In addition, the comparison of normal stress–plastic strain diagrams revealed large compressive plastic strains repeatedly induced in the substrate regions below the interface in the Fix model due to substrate fixation during LC. The repeated plastic deformation induced the Bauschinger effect, which increased the simulation accuracy with the kinematic hardening law. These findings are crucial for accurately predicting residual stresses and thermal distortions in LC processes with substrate fixation.https://www.jstage.jst.go.jp/article/mej/11/6/11_24-00251/_pdf/-char/enlaser claddinghardening lawsresidual stressthermal distortionfinite element analysis |
| spellingShingle | Taisei IZUMI Ayumu YANO Masayuki ARAI Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process Mechanical Engineering Journal laser cladding hardening laws residual stress thermal distortion finite element analysis |
| title | Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process |
| title_full | Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process |
| title_fullStr | Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process |
| title_full_unstemmed | Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process |
| title_short | Effect of subsequent yield surface on residual stress in 3D numerical simulation of laser cladding process |
| title_sort | effect of subsequent yield surface on residual stress in 3d numerical simulation of laser cladding process |
| topic | laser cladding hardening laws residual stress thermal distortion finite element analysis |
| url | https://www.jstage.jst.go.jp/article/mej/11/6/11_24-00251/_pdf/-char/en |
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