Description
Modelling, Measurement and Management of Residual Stress During Manufacturing of Titanium ComponentsResidual stress, a tensor quantity, are locked-in stresses within a component without external loading, generated as a result of complex non-linear thermal-mechanical processing during manufacturing. Most manufacturing processes introduce residual stress that has a direct bearing on manufacturing (e.g., undesirable distortion) and on the resilience of products in service and their design life. Historically, residual stresses have primarily been incorporated into structure critical component design through a significant safety factor because they are challenging to characterise and control, and there is little design guidance in codes and standards. Consequently, components have thicker sections than needed, increasing the resource use and entry cost of the product as well as the cost of ownership through extra weight. The grand challenge is to bring residual stress into the 4th industrial revolution to engineer its effect during material manufacture to minimise waste and production time and maximise product performance in-service.
Based on current state-of-the-art technology, for forging high value components, this is done by developing a baseline model simulating the metal forging and heat treatment processes, considering microstructural changes using physically based and constitutive materials models. A baseline model is also developed for the subsequent machining operation (metal removal rate, heat generated, etc.) using simplified approaches for metal cutting through material removal operations and integrating cutting forces, machining induced effects, and clamping configurations. These baseline models are then integrated into a more holistic approach to create a quasi-“digital-twin” that also estimates microstructure changes, generation and evolution of residual stress, and distortion throughout the whole processes. This presentation provides the latest development in this vein and sheds light on the prediction, measurements, and control of residual stress during manufacturing process of high value components made from titanium.
| Period | 12 Jun 2023 → 16 Jun 2023 |
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| Event type | Conference |
| Location | Edinburgh, United KingdomShow on map |
| Degree of Recognition | International |