Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser–Powder Bed Fusion Additive Manufacturing Technology
Abstract
:1. Introduction
2. Materials and Methods
2.1. Residual Stress Analysis in the Braking Pedal Using the Hole Drilling Method
2.2. Residual Stress Analysis in the Braking Pedal Using the Sectioning Method
2.3. Simulation of Residual Stress in the Braking Pedal Using Computational Methods
3. Results
3.1. Resulting Values of Residual Stress in the Braking Pedal Using the Hole Drilling Method
3.1.1. Calculation of Uniform Stress
3.1.2. Calculation of Non-Uniform Stress
3.2. Residual Stress Analysis in the Braking Pedal Using the Sectioning Method
3.3. Analysis of Residual Stress in the Braking Pedal Using the Ansys Workbench 2020R2 Computational Program
3.4. Residual Stress Analysis in the Braking Pedal Using the Simufact Additive 2021 Computational Program
3.5. Comparison of the Achieved Residual Stress Results in the Braking Pedal for All Methods and Both Measurement Points
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Uniform Stress | ||||||
---|---|---|---|---|---|---|
Drilling Depth (mm) | Measurement Point No. 1 (74 mm) | Measurement Point No. 2 (57.5 mm) | ||||
σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | |
0.1 | 261 | 749 | 659 | 490 | 420 | 525 |
0.2 | 235 | 686 | 604 | 472 | 416 | 522 |
0.3 | 209 | 643 | 569 | 440 | 389 | 496 |
0.4 | 194 | 618 | 548 | 414 | 365 | 473 |
0.5 | 187 | 602 | 534 | 394 | 346 | 451 |
0.6 | 183 | 589 | 522 | 375 | 329 | 432 |
0.7 | 180 | 577 | 512 | 358 | 315 | 414 |
0.8 | 181 | 570 | 505 | 346 | 307 | 402 |
0.9 | 182 | 564 | 499 | 336 | 301 | 391 |
1.0 | 186 | 560 | 494 | 327 | 298 | 384 |
Non-Uniform Stress | ||||||
---|---|---|---|---|---|---|
Drilling Depth (mm) | Measurement Point No. 1 (74 mm) | Measurement Point No. 2 (57.5 mm) | ||||
σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | |
0.05 | 290 | 797 | 699 | 491 | 407 | 510 |
0.10 | 235 | 693 | 611 | 490 | 436 | 543 |
0.15 | 197 | 622 | 550 | 457 | 415 | 523 |
0.20 | 170 | 578 | 515 | 416 | 378 | 491 |
0.25 | 154 | 551 | 494 | 379 | 341 | 455 |
0.30 | 143 | 533 | 479 | 345 | 306 | 419 |
0.35 | 137 | 521 | 468 | 316 | 274 | 384 |
0.40 | 134 | 510 | 458 | 288 | 246 | 351 |
0.45 | 134 | 501 | 449 | 263 | 220 | 321 |
0.50 | 136 | 493 | 441 | 239 | 199 | 294 |
0.55 | 140 | 485 | 433 | 217 | 181 | 271 |
0.60 | 147 | 479 | 425 | 197 | 168 | 250 |
0.65 | 155 | 474 | 418 | 179 | 159 | 233 |
0.70 | 165 | 470 | 413 | 161 | 152 | 218 |
0.75 | 175 | 467 | 408 | 142 | 148 | 206 |
0.80 | 187 | 465 | 405 | 123 | 144 | 197 |
0.85 | 203 | 467 | 405 | 105 | 143 | 192 |
0.90 | 223 | 474 | 410 | 90 | 147 | 190 |
0.95 | 250 | 488 | 423 | 79 | 156 | 193 |
1.00 | 285 | 509 | 442 | 73 | 169 | 200 |
Depth (mm) | Measurement Point No. 1 (74 mm) | Measurement Point No. 2 (57.5 mm) |
---|---|---|
σa(1) (MPa) | σa(1) (MPa) | |
0 | 51 | 469 |
0.1 | 49 | 447 |
0.2 | 46 | 424 |
0.3 | 44 | 401 |
0.4 | 42 | 378 |
0.5 | 40 | 355 |
0.6 | 38 | 332 |
0.7 | 35 | 309 |
0.8 | 33 | 286 |
0.9 | 31 | 263 |
1.0 | 29 | 240 |
SSFX | SSFY | SSFZ |
---|---|---|
0.98 | 0.98 | 0.997 |
Number of Voxels | Number of Nodes |
---|---|
152,057 | 178,462 |
Parameter | Value |
---|---|
Material | SS316L |
Yield strength | 467 MPa |
Tensile strength | 614 MPa |
Young’s modulus | 204 GPa |
Shear modulus | 10.96 GPa |
Poisson’s ratio | 0.29 |
Layer thickness | 50 µm |
SSFX | 0.98 |
SSFY | 0.98 |
SSFZ | 0.997 |
Depth (mm) | Measurement Point No. 1 (74 mm) | Measurement Point No. 2 (57.5 mm) | ||||
---|---|---|---|---|---|---|
σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | |
0.0 | 72 | 544 | 508 | 436 | 339 | 481 |
0.2 | 67 | 529 | 498 | 399 | 309 | 454 |
0.4 | 62 | 513 | 489 | 362 | 279 | 428 |
0.6 | 57 | 498 | 479 | 325 | 248 | 402 |
0.8 | 52 | 483 | 470 | 288 | 218 | 376 |
1.0 | 47 | 467 | 460 | 250 | 188 | 350 |
εxx [−] | εyy [−] | εzz [−] |
---|---|---|
−0.00286296 | −0.00277407 | −0.03 |
Number of Voxels | Number of Nodes |
---|---|
543,098 | 610,580 |
Parameter | Value |
---|---|
Laser power | 200 W |
Scanning speed | 650 mm/s |
Layer thickness | 50 µm |
Hatching distance | 0.11 mm |
Increment rotating angle | 67° |
Temperature | Room temperature |
ɛxx | −0.00286296 |
ɛyy | −0.00277407 |
ɛzz | −0.03 |
Depth (mm) | Measurement Point No. 1 (74 mm) | Measurement Point No. 2 (57.5 mm) | ||||
---|---|---|---|---|---|---|
σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | σa(1) (MPa) | σC(3) (MPa) | σVMS (MPa) | |
0 | −18 | 574 | 578 | 457 | - | 504 |
0.4 | 30 | 600 | 576 | 396 | - | 436 |
0.8 | 63 | 497 | 472 | 329 | - | 362 |
1.2 | 115 | 505 | 478 | 338 | - | 372 |
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Fojtík, F.; Potrok, R.; Hajnyš, J.; Ma, Q.-P.; Kudrna, L.; Měsíček, J. Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser–Powder Bed Fusion Additive Manufacturing Technology. Materials 2023, 16, 5766. https://doi.org/10.3390/ma16175766
Fojtík F, Potrok R, Hajnyš J, Ma Q-P, Kudrna L, Měsíček J. Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser–Powder Bed Fusion Additive Manufacturing Technology. Materials. 2023; 16(17):5766. https://doi.org/10.3390/ma16175766
Chicago/Turabian StyleFojtík, František, Roman Potrok, Jiří Hajnyš, Quoc-Phu Ma, Lukáš Kudrna, and Jakub Měsíček. 2023. "Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser–Powder Bed Fusion Additive Manufacturing Technology" Materials 16, no. 17: 5766. https://doi.org/10.3390/ma16175766