The OxCM contour method solver for residual stress evaluation

IF 8.7 2区 工程技术 Q1 Mathematics Engineering with Computers Pub Date : 2024-03-29 DOI:10.1007/s00366-024-01959-3
Fatih Uzun, Alexander M. Korsunsky
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Abstract

This paper introduces the OxCM contour method solver, a console application structured based on the legacy version of the FEniCS open-source computing platform for solving partial differential equations (PDEs) using the finite element method (FEM). The solver provides a standardized approach to solving linear elastic numerical models, calculating residual stresses corresponding to measured displacements resulting from changes in the boundary conditions after minimally disturbing (non-contact) cutting. This is achieved through a single-line command, specifically in the case of availability of a domain composed of a tetrahedral mesh and experimentally collected and processed profilometry data. The solver is structured according to a static boundary condition rule, allowing it to rely solely on the cross-section occupied by the experimental data, independent of the geometric irregularities of the investigated body. This approach eliminates the need to create realistic finite element domains for complex-shaped, discontinuous processing bodies. While the contour method provides highly accurate quantification of residual stresses in parts with continuously processed properties, real scenarios often involve parts subjected to discontinuous processing and geometric irregularities. The solver’s validation is performed through numerical experiments representing both continuous and discontinuous processing conditions in artificially created domains with regular and irregular geometric features based on the eigenstrain theory. Numerical experiments, free from experimental errors, contribute to a novel understanding of the contour method's capabilities in reconstructing residual stresses in such bodies through a detailed error analysis. Furthermore, the application of the OxCM contour method solver in a real-case scenario involving a nickel-based superalloy finite-length weldment is demonstrated. The results exhibit the expected distribution of the longitudinal component of residual stresses along the long-transverse direction, consistent with the solution of a commercial solver that was validated by neutron diffraction strain scanning.

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用于残余应力评估的 OxCM 等值线法求解器
本文介绍了 OxCM 轮廓法求解器,它是基于 FEniCS 开源计算平台传统版本的控制台应用程序结构,用于使用有限元法求解偏微分方程 (PDE)。求解器采用标准化方法求解线性弹性数值模型,计算与最小干扰(非接触)切割后边界条件变化导致的测量位移相对应的残余应力。这可以通过单行命令来实现,特别是在有一个由四面体网格和实验收集和处理的轮廓测量数据组成的域的情况下。求解器的结构遵循静态边界条件规则,使其能够完全依赖于实验数据所占的横截面,而与被测体的几何不规则性无关。这种方法无需为形状复杂、不连续的加工体创建逼真的有限元域。虽然等值线方法可以对具有连续加工特性的零件的残余应力进行高精度量化,但实际情况往往涉及不连续加工和几何不规则的零件。基于特征应变理论,在人为创建的具有规则和不规则几何特征的域中,通过数值实验来表示连续和不连续的加工条件,从而对求解器进行验证。数值实验不存在实验误差,通过详细的误差分析,有助于对等值线方法重建此类机构中残余应力的能力有一个新的认识。此外,还演示了 OxCM 等值线方法求解器在镍基超合金有限长度焊接件实际情况中的应用。结果表明,残余应力的纵向分量沿长横方向呈预期分布,与通过中子衍射应变扫描验证的商用求解器的求解结果一致。
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来源期刊
Engineering with Computers
Engineering with Computers 工程技术-工程:机械
CiteScore
16.50
自引率
2.30%
发文量
203
审稿时长
9 months
期刊介绍: Engineering with Computers is an international journal dedicated to simulation-based engineering. It features original papers and comprehensive reviews on technologies supporting simulation-based engineering, along with demonstrations of operational simulation-based engineering systems. The journal covers various technical areas such as adaptive simulation techniques, engineering databases, CAD geometry integration, mesh generation, parallel simulation methods, simulation frameworks, user interface technologies, and visualization techniques. It also encompasses a wide range of application areas where engineering technologies are applied, spanning from automotive industry applications to medical device design.
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