Thin (slender) steel plates possess shear strength beyond the elastic buckling load which is commonly referred to as the post-buckling capacity. Semi-empirical equations based on experimental tests of plate girders have been used for decades to predict the ultimate post-buckling strength of slender webs. However, several recent studies have shown that the current models for predicting the ultimate shear post-buckling capacity of thin plates are based on some incorrect assumptions regarding their mechanical behavior. As a result, the current design equations provide an approximate estimate of capacity for the range of parameters in the test data upon which they are founded. This paper explores the fundamental behavior of thin plates under pure shear. Such a fundamental examination of shear post-buckling behavior in thin plates is needed to enable design procedures that can optimize a plate’s shear strength and load-deformation performance for a wider range of loading and design parameters. Using finite element analyses, which are validated against available results of previous experimental tests, outputs such as plastic strains, von Mises stresses, principal stresses, and principal stress directions are examined on a buckled plate acting in pure shear. The internal bending, shear, and membrane stresses in the plate’s finite elements are also evaluated. In this study, these evaluations are performed for a simply-supported plate with an aspect ratio equal to 1.0 and slenderness ratio equal to 134. Results show that localized bending in the plates due to the out-of-plane post-buckling deformations appear to be a significant factor in the ultimate shear post-buckling capacity of the plate. Also, the compressive stresses continue to increase beyond the onset of elastic buckling in some regions of the plate, contrary to current design assumptions. Overall, this study provides new insights into the mechanics of shear post-buckling behavior of thin plates that can be exploited for design procedures that are consistent with mechanical behavior.
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Residual stress effects during additive manufacturing of reinforced thin nickel–chromium plates
Additive manufacturing (AM) is a powerful technique for producing metallic components with complex geometry relatively quickly, cheaply and directly from digital representations; however, residual stresses induced during manufacturing can result in distortions of components and reductions in mechanical performance, especially in parts that lack rotational symmetry and, or have cross sections with large aspect ratios. Geometrically reinforced thin plates have been built in nickel–chromium alloy using laser-powder bed fusion (L-PBF) and their shapes measured using stereoscopic digital image correlation before and after release from the base-plate of the AM machine. The results show that residual stresses cause potentially severe out-of-plane deformation that can be alleviated using either an enveloping support structure, which increased the build time substantially, was difficult to remove and wasted material, or using buttress supports to the reinforced edges of the thin plate. The buttresses were quick to build and remove, minimised waste but needed careful design. Plates built in a landscape orientation required out-of-plane buttresses while those built in a portrait orientation required both in-plane and out-of-plane buttresses. In both cases, out-of-plane deformation increased on release from the baseplate but this was mitigated by incremental release which resulted in out-of-plane deformations of less than 5% of the in-plane dimensions.
more » « less- NSF-PAR ID:
- 10376537
- Publisher / Repository:
- Springer Science + Business Media
- Date Published:
- Journal Name:
- The International Journal of Advanced Manufacturing Technology
- Volume:
- 123
- Issue:
- 5-6
- ISSN:
- 0268-3768
- Page Range / eLocation ID:
- p. 1845-1857
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract Background Distortion arises during machining of metallic parts from two main mechanisms: 1) release of bulk residual stress (BRS) in the pre-form, and 2) permanent deformation induced by cut tools. Interaction between these mechanisms is unexplored.
Objective Assess this interaction using aluminum samples that have a flat surface with variations of BRS, where that surface is subsequently milled, and we observe milling-induced residual stress (MIRS) and distortion.
Methods Plate samples are cut from two kinds of large blocks, one kind stress-relieved by stretching and a second kind solution heat treated, quenched and aged. The BRS field in the plates is known from a recent series of measurements, being small in the stress relieved plates (within ±20 MPa) and large (±100 MPa) in the quenched plates, varying from tension to compression over the surface that is milled. MIRS is measured following milling using hole-drilling. Distortions of thin wafers cut at the milled surfaces are used to elucidate BRS/MIRS interactions. A finite element (FE) model and a strength of materials model are each used to assess consistency between wafer distortion and measured MIRS.
Results Milling in samples with high BRS magnitude changes the directions of MIRS and distortion relative to the milling direction, with the direction of maximum curvature rotating toward or away from the milling direction depending on the sign and direction of BRS. High magnitude BRS was also found to increase the wafer peak arc height, nearly doubling the amount found in low BRS samples.
Conclusion Measured residual stress and observed wafer distortion both show interactions between MIRS and BRS. Stress analysis models show that the differences in measured MIRS are consistent with the differences in observed distortion.
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