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ANALYSIS OF RESIDUAL STRESS IN

HARD FACED COMPONENT USING


CONTOUR METHOD
PHASE: I
PRESENTED BY

E.JAMUNA
0572209
M.E., (MANUFACTURING ENGG)

UNDER THE GUIDANCE OF

Mrs. K. MANONMANI,
LECTURER IN MECHANICAL ENGG,
GCT,COIMBATORE 13.

OBJECTIVE

Measurement of residual stress in hardfaced


component (Stellite 6) using Contour Method.

RESIDUAL STRESS

Due to uneven cooling and the local heat input.

Affect both mechanical and metallurgical properties


of welded components.

strong influence on weld deformation, fatigue


strength, fracture toughness and buckling strength.

RESIDUAL STRESS
MEASURING METHODS

Stress Relaxation Methods


Hole drilling method.
Brittle coating method.
Photo elasticity method
Diffraction Methods
X-ray diffraction method
Neutron diffraction method

Dissection method.

RESIDUAL STRESS MEASURING


METHODS

Methods Using Stress Sensitive Properties


Ultrasonic method
Micro magnetic method

CONTOUR METHOD
Powerful Techniques

Uniquely related to to the original residual stresses

Simple

Inexpensive

Equipment widely available

STEPS INVOLVED

Material Selection

Process Selection

Stress Measurement
(i) Specimen Cutting
(ii) Contour Measurement
(iii) Stress Analysis
- Principle
- Material Properties
- Finite Element Model
- Boundry conditions and applied loads
Results and Discussion

MATERIAL SELECTION

Base Metal Low Carbon Steel


Surfacing Metal Stellite 6 (Co Cr- A)

PROCESS SELECTION

SURFACING PROCESSES

CLADDING

HARDFACING Plasma Transferred Arc


Welding

BUILD-UP

BUTTERING

HARDFACING

Metal is deposited over another surface to increase


the hardness ,wear resistance and corrosion
resistance of the surface.

NEED FOR HARDFACING

Better Wear resistance than the original base


metal and increase double and triple the working
life of a component.

Improve Corrosion resistance of the material


surface.

Improve Mechanical and Metallurgical properties of


hardfaced layers.

HARDFACING APPLICATIONS

Valve Industries

Chemical ,refineries & fertilizer plants

Nuclear and steam power plants

Pressure vessels

Agriculture Machines

Earth moving Equipments

Aircraft and Missile Components.

STRESS MEASUREMENT
(i) Specimen Cutting

Make a cut perpendicular to the weld area.


No material removal

WIRE ELECTRIC DISCHARGE MACHINE

(ii) Contour Measurement


By CMM (Co-ordinate Measuring Machine)
MACHINE SPECIFICATION
Model SPECTRA
Probe tip Length 10 mm, Diameter 1 mm
Accuracy 3 microns

(iii) Stress Analysis

Principle

Principle

In step A, the undistributed part is made up of two halves


containing the original residual stresses.

In step B, the part has been cut in two resulting in a


deformation of both surfaces as the residual stresses are
released, resulting in zero normal stresses.

In step C, the material is forced back to its original position.


This involves applying the deformation measured in step b to
an FE model to calculate the corresponding stresses. This
superposition principle assumes that the material behaves
elastically during the relaxation of residual stress and that the
material removal process does not introduce stresses of
sufficient magnitude to affect the measured displacements.

Material Properties

Material 1 (Low Carbon Steel)-Base Metal:


(I) Modulus of elasticity:160 Mpa
(ii) Poissons ratio
: 0.29

Material 2 (Stellite-6)-Powder Material:


(I) Modulus of elasticity: 140 Mpa
(ii) Poissons ratio
: 0.28

Finite Element Model

Measurement points are taken 0.5mm increment


along the width surface, and 1mm increment along
the length side.

By Direct Node Generation.

Total node - 32634

Element - SOLID45.

SOLID45

HARDFACED COMPONENT FEA MODEL

HARDFACED COMPONENT EXPERIMENTS

BOUNDRY CONDITIONS AND


APPLIED LOADS

Arrest 4 corner nodes in bottom side of the


component.
Applied load by displacement measured from CMM.

RESULTS AND DISCUSSIONS


Transverse Stresses
-

Both Tensile and Compressive in nature.

- Graphs are drawn between the node 1 to 32634.

Von Mises stresses in Hardfaced


Component

Von Mises stresses in Hardfaced


Component

Stress Intensity in Hardfaced


Component

Stress Intensity in Hardfaced


Component

Shear stress in XZ direction

Shear stress in XZ direction

CONCLUSION

Affect its mechanical properties, metallurgical


properties and the service life of the component.

Minimize the premature failures.

By direct node generation technique (ANSYS 8.0 ).

High accuracy compared to other technique.

Relatively simple procedure.

No tedious material removal.

By various stress relieving methods

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THANK YOU