Pedro Manuel Calas Lopes Pacheco

Shape Memory Alloy Helical Springs Performance: Modeling and Experimental Analysis

Shape memory alloys (SMAs) are metallic materials that have the capability to recover its original shape eliminating residual strains when subjected to adequate thermal process. This behavior is related to phase transformation induced either by stress or by. During the phase transformation process of an SMA component, large loads and/or displacements can be generated in a relatively short period of time making this component an interesting mechanical actuator. Because of such remarkable properties, SMAs have found a number of applications in different areas. The present contribution deals with the modeling, simulation and experimental analysis of SMA helical springs. Basically, it is assumed a one-dimensional constitutive model to describe its thermomechanical shear behavior and, afterwards, helical springs are modeled by considering classical approach. SMA helical spring thermomechanical behavior is investigated through experimental tests performed at different loads. Numerical results show that the model is in close agreement with experimental data. Since the thermal process has an essential importance in the performance of an SMA actuator, different cooling medium conditions are investigated, evaluating the actuators performance.

Nonlinear geometric influence on the mechanical behavior of shape memory alloy helical springs

This paper investigates the nonlinear geometric effect on the mechanical behavior of shape memory alloy (SMA) helical springs. First, the SMA wires are characterized, and then the design and fabrication of SMA helical springs are discussed. Experimental tensile tests are carried out to show the nonlinear geometric influence. Results show a coupling between constitutive and geometric nonlinearities that defines the spring stiffness. Two springs with different geometries are built from SMA wires to define springs with both weak and strong nonlinear geometric influence. Numerical analyses are developed, using the finite element method to confirm the general conclusions shown in our experimental observations.

Analysis of the Temperature Distribution in Friction Stir Welding Using the Finite Element Method

Welding is a fabrication process widely used in several industrial areas. The welding of metallic alloys presents some basic characteristics as the presence of a localized intensive heat input that promotes mechanical and metallurgical changes. Different from conventional welding processes, where macroscopic fusion is observed, friction welding is a solid state welding process where the joint is produced by the relative rotational and/or translational motion of two pieces under the action of compressive forces producing heat and plastic strain on the friction surfaces. Friction Stir Welding (FSW) process has received much attention for its special characteristics, like the high quality of the joints. Although there are several experimental works on the subject, numerical modeling is not well stated, as the process is very complex involving the coupling of several non-linear phenomena. In this contribution a tridimensional finite element model is presented to study the temperature distribution in plates welded by the FSW process. A weld heat source is proposed to represent the heat generated during the process. The heat source model considers several contributions present in the process as the friction between the tool and the piece and the plastic power associated to the plastic strain developed. Numerical results show that the model is in close agreement with experimental results, indicating that the model is capable of capturing the main characteristics of the process. The proposed model can be used to predict important process characteristics, like the TAZ (Thermal Affected Zone), as a function of the welding parameters.

Modelling Bonded Shape Memory Alloy Vibration Attenuators Elements Using the Finite-Element Method

Shape memory alloys (SMAs) present the capability to develop large forces and displacements with low power consumption. Due their special characteristics, SMAs have been used in many different applications. Pseudoelastic hysteresis loop observed in austenitic SMAs is associated with energy dissipation. Therefore, pseudoelastic SMA elements can be used as vibration attenuators. Joining methods present some technological challenges for the use of these elements. Welding can strongly affect the properties of the alloy. Mechanical joints using rivets and screws are commonly used but promote stress concentration effects. The use of adhesives offers some benefits, being an alternative to be investigated. This work presents a numerical model based on the finite-element method and experimental procedures to study the behaviour of bonded vibration attenuators with SMA elements. The proposed model considers the pseudoelastic behaviour of SMA elements, and a cohesive zone model was used to study the union between absorber and an aluminium plate. Finally, several loading conditions were analysed with the proposed models to assess the capability of bonded pseudoelastic SMA elements to dissipate energy. The proposed geometry allows the elements to actuate as an efficient vibration attenuator, in particular when submitted to axial loading.

Modeling Residual Stresses in Superduplex Stainless Steel Welded Pipes Using the Finite Element Method

Welding is a complex process where localized and intensive heat is imposed to a piece promoting mechanical and metallurgical changes. Phenomenological aspects of welding process involve couplings among different physical processes and its description is unusually complex. Basically, three couplings are essential: thermal, phase transformation and mechanical phenomena. Welding processes can generate residual stress due to the thermal gradient imposed to the workpiece in association to geometric restrictions. The presence of tensile residual stresses can be especially dangerous to mechanical components submitted to fatigue loadings. The present work regards on study the residual stress in welded superduplex stainless steel pipes using experimental and a numerical analysis. A parametric nonlinear elastoplastic model based on finite element method is used for the evaluation of residual stress in superduplex steel welding. The developed model takes into account the coupling between mechanical and thermal fields and the temperature dependency of the thermomechanical properties. Thermocouples are used to measure the temperature evolution during welding stages. Instrumented hole drilling technique is used for the evaluation of the residual stress after welding process. Experimental data is used to calibrate the numerical model. The methodology is applied to evaluate the behavior of two-pass girth welding (TIG for root pass and SMAW for finishing) in 4 inch diameter seamless tubes of superduplex stainless steel UNS32750. The result shows a good agreement between numerical experimental results. The proposed methodology can be used in complex geometries as a powerful tool to study and adjust welding parameters to minimize the residual stresses on welded mechanical components.

Dynamics of 2-DOF Micro-end-Milling System Considering Grain-Size Variation

Non-smooth systems are employed to model different cutting processes including milling and oil drilling. This article deals with the modeling of the micro-end-milling dynamics with inhomogeneous materials. The model considers a non-smooth system composed of a primary system that represents the tool and a secondary system, representing the workpiece. This system mimics micro-end-milling dynamics considering a progressive motion of the tool holder with tool run-out. The relative position of the tool holder and the chip is evaluated avoiding huge displacements of the tool tip when the tool is not in cutting. The simplified dynamics presented in this article is used as a methodology to calculate the cutting force and tool performance from the prescribed trajectory. The inhomogeneity is related to the description of the micro-machining process where material properties cannot be considered as constant due to grain structure as the tool moves for cutting. Numerical simulations consider a situation where the grain workpiece has austenitic, ferritic or ferritic-austenitic phases. Microscopic analysis is employed to obtain the property variations. The main goal is to establish a qualitative comprehension of the system dynamics comparing results with homogeneous material cutting process.