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Metals Processing, Finite Element Analysis and Fatigue Design

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Simulation and Design".

Deadline for manuscript submissions: closed (10 April 2023) | Viewed by 6092

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Dr. Abel Dias dos Santos

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Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal
Interests: manufacturing processes; metal forming technology and processing; sheet metal forming; numerical simulation; experimental validation; material testing and constitutive modelling
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Dr. Abílio M. P. De Jesus

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Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal
Interests: manufacturing processes; simulation; fracture mechanics
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Dear Colleagues,

Metallic materials are yet essential for goods production, but their processing requires continuous research towards sustainable technologies and processes. One key aspect is a proper process design in order to guarantee the compliance of the final products with intended functionality, but at the same time to preserve resources usage. Metal processing optimization and the strength of the final products, including their fatigue performance, could be anticipated at the design stage resorting to advanced modeling, including numerical simulation (e.g., FEA). Additionally, the continuous development of the technologies and processes, the research on suitable numerical tools and models, and experimental procedures allow a proper process design for tailored products performance, which is mandatory for industry competitiveness and sustainability of society. This Special Issue aims at gathering contributions on recent advances and to identify directions both in experimental and in numerical research combining manufacturing processes of metallic materials with advanced design, fatigue, and fracture performance of components. Regarding the processes, metal forming, additive and subtractive processing, welding, casting, among others, all these manufacturing topics are welcome.

We are pleased to announce a Special Issue in Metals about Metal Processing, Finite Element Analysis and Fatigue Design. We believe your expertise fits the topics of this Special Issue, thus we believe that your high-quality contribution will be an added-value to the state-of-the art of this research, showing the current advances and major trends in the field.

Sincerely yours,

Prof. Dr. Abel Dias dos Santos
Prof. Dr. Abílio Manuel Pinho de Jesus
Guest Editors

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Keywords

manufacturing
metals
manufacturing processes
fatigue
fracture
design
finite element analysis
structural Integrity
surface Integrity
residual stresses

Published Papers (4 papers)

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Research

15 pages, 4776 KiB

Open AccessArticle

Numerical and Experimental Analysis of Horizontal-Axis Wind Turbine Blade Fatigue Life

by Imran Shah, Abdullah Khan, Muhsin Ali, Sana Shahab, Shahid Aziz, Muhammad Adnan Aslam Noon and Javed Ahmad Khan Tipu

Materials 2023, 16(13), 4804; https://doi.org/10.3390/ma16134804 - 03 Jul 2023

Cited by 1 | Viewed by 1369

Abstract

Horizontal-axis wind turbines are the most popular wind machines in operation today. These turbines employ aerodynamic blades that may be oriented either upward or downward. HAWTs are the most common non-conventional source of energy generation. These turbine blades fail mostly due to fatigue, as a large centrifugal force acts on them at high rotational speeds. This study aims to increase a turbine’s service life by improving the turbine blades’ fatigue life. Predicting the fatigue life and the design of the turbine blade considers the maximum wind speed range. SolidWorks, a CAD program, is used to create a wind turbine blade utilizing NACA profile S814. The wind turbine blade’s fatigue life is calculated using Morrow’s equation. A turbine blade will eventually wear out due to several forces operating on it. Ansys software is used to analyze these stresses using the finite element method. The fatigue study of wind turbine blades is described in this research paper. To increase a turbine blade’s fatigue life, this research study focuses on design optimization. Based on the foregoing characteristics, an improved turbine blade design with a longer fatigue life than the original one is intended in this study. The primary fatigue parameters are the length of a chord twist angle and blade length. The experimental data computed with the aid of a fatigue testing machine are also used to validate the numerical results, and it is found that they are very similar to one another. By creating the most effective turbine blades with the longest fatigue life, this research study can be developed further. The most effective turbine blades with the longest fatigue life can be designed to further this research investigation. Full article

(This article belongs to the Special Issue Metals Processing, Finite Element Analysis and Fatigue Design)

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14 pages, 4270 KiB

Open AccessArticle

Numerical Analysis on Fatigue Crack Growth at Negative and Positive Stress Ratios

by Abdulnaser M. Alshoaibi and Yahya Ali Fageehi

Materials 2023, 16(10), 3669; https://doi.org/10.3390/ma16103669 - 11 May 2023

Cited by 4 | Viewed by 1203

Abstract

The finite element method was used to investigate the effect of the stress ratio on fatigue crack propagation behavior within the framework of the linear elastic fracture mechanics theory. The numerical analysis was carried out using ANSYS Mechanical R19.2 with the unstructured mesh method-based separating, morphing, and adaptive remeshing technologies (SMART). Mixed mode fatigue simulations were performed on a modified four-point bending specimen with a non-central hole. A diverse set of stress ratios (R = 0.1, 0.2, 0.3, 0.4, 0.5, −0.1, −0.2, −0.3, −0.4, −0.5), including positive and negative values, is employed to examine the influence of the load ratio on the behavior of the fatigue crack propagation, with particular emphasis on negative R loadings that involve compressive excursions. A consistent decrease in the value of the equivalent stress intensity factor (

Δ K_{e q}

) is observed as the stress ratio increases. The observation was made that the stress ratio significantly affects both the fatigue life and the distribution of von Mises stress. The results demonstrated a significant correlation between von Mises stress,

Δ K_{e q}

, and fatigue life cycles. With an increase in the stress ratio, there was a significant decrease in the von Mises stress, accompanied by a rapid increase in the number of fatigue life cycles. The results obtained in this study have been validated by previously published literature on crack growth experiments and numerical simulations. Full article

(This article belongs to the Special Issue Metals Processing, Finite Element Analysis and Fatigue Design)

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31 pages, 9608 KiB

Open AccessArticle

Direct Energy Deposition Parametric Simulation Investigation in Gear Repair Applications

by Nuno Miguel Ferreira, Maria Vila Pouca, Carlos Fernandes, Jorge Seabra, Grzegorz Lesiuk, Marco Parente and Abílio Jesus

Materials 2023, 16(9), 3549; https://doi.org/10.3390/ma16093549 - 05 May 2023

Cited by 3 | Viewed by 1434

Abstract

Additive manufacturing technologies have numerous advantages over conventional technologies; nevertheless, their production process can lead to high residual stresses and distortions in the produced parts. The use of numerical simulation models is presented as a solution to predict the deformations and residual stresses resulting from the printing process. This study aimed to predict the tensions and distortions imposed in the gear repair process by directed energy deposition (DED). First, the case study proposed by National Institute of Standards and Technology (NIST) was analyzed to validate the model and the numerically obtained results. Subsequently, a parametric study of the influence of some of the parameters of DED technology was carried out. The results obtained for the validation of the NIST benchmark bridge model were in agreement with the results obtained experimentally. In turn, the results obtained from the parametric study were almost always in line with what is theoretically expected; however, some results were not very clear and consistent. The results obtained help to clarify the influence of certain printing parameters. The proposed model allowed accounting for the effect of residual stresses in calculating the stresses resulting from gear loading, which are essential data for fatigue analysis. Modeling and simulating a deposition process can be challenging due to several factors, including calibrating the model, managing the computational cost, accounting for boundary conditions, and accurately representing material properties. This paper aimed to carefully address these parameters in two case studies, towards reliable simulations. Full article

(This article belongs to the Special Issue Metals Processing, Finite Element Analysis and Fatigue Design)

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19 pages, 5485 KiB

Open AccessArticle

Experimental and Numerical Study on the Influence of Lubrication Conditions on AA6068 Aluminum Alloy Cold Deformation Behavior

by Mariana Florica Pop, Adriana Voica Neag and Ioana-Monica Sas-Boca

Materials 2023, 16(5), 2045; https://doi.org/10.3390/ma16052045 - 01 Mar 2023

Cited by 1 | Viewed by 1451

Abstract

The aim of this manuscript is the experimental and numerical study regarding the influence of friction conditions on plastic deformation behavior by upsetting the A6082 aluminum alloy. The upsetting operation is characteristic of a significant number of metal forming processes: close die forging, open die forging, extrusion, and rolling. The purpose of the experimental tests was to determine: by the ring compression method, the friction coefficient for 3 surface lubrication conditions (dry, mineral oil, graphite in oil) by using the Coulomb friction model; the influence of strains on the friction coefficient; the influence of friction conditions on the formability of the A6082 aluminum alloy upsetted on hammer; study of non-uniformity of strains in upsetting by measuring hardness; change of the tool-sample contact surface and non-uniformity of strains distribution in a material by numerical simulation. Regarding the tribological studies involving numerical simulations on the deformation of metals, they mainly focused on the development of friction models that characterize the friction at the tool-sample interface. The software used for the numerical analysis was Forge@ from Transvalor. Full article

(This article belongs to the Special Issue Metals Processing, Finite Element Analysis and Fatigue Design)

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