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Mechanical simulation using a semi analytical method : from elasto-plastic rolling contact to multiple impacts

Abstract : The life time of mechanical components can be increased by the presence of compressive residual stresses. Inherent to most production processes, residual stresses play a critical role on the mechanical parts behaviour. The knowledge and mastering of residual stresses and linked processes are thus fundamental. The development of efficient numerical methods to predict these residual stresses will allow to save costly experiments and to study the influence of the main parameters. This PhD presents the development and application of semi analytical methods (SAM) to the modelling of mechanical processes of compressive residual stress generation. The SAMs, initially developed for the simulation of elasto-plastic contacts, have the advantage of significantly low computation time compared to classical numerical methods. This method is first used to simulate the low plasticity burnishing process, with a rolling loading. Then, it is used for the simulation of impacts, first unique and then repeated. The frictionless rolling contact between two elasto-plastic bodies is first studied. The influence of plasticity, of the hardening model (isotropic or kinematic), of the geometry of the bodies in contact (spheres or ellipsoids) and of the loading type (indentation or rolling) on the contact pressure and plastic strains are analysed. Impacts simulation is then addressed. The developed method is first validated numerically then confronted to experimentations. Three materials have been particularly studied: 316L, AA 7010 and Inconel 600. The impacts dimensions and the generated strains, measured by digital image correlation, are used to validate experimentally the method. The ultrasonic shotpeening process has been specifically studied. The description of the kinematics of the shots put in movement by a sonotrode in a closed peening chamber has first been studied. The use of analytical formulae for the estimation of the coefficients of restitution, during the numerous impacts between shots and with the chamber’s walls, allowed refining the calculation of the average impact velocity as a function of the process parameters. The SAM is the used to determine the plastic strain field induced by the impacts. At last a projection method is proposed to finally determine the residual stress field in thick or thin structures.
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Thibaut Chaise. Mechanical simulation using a semi analytical method : from elasto-plastic rolling contact to multiple impacts. Other. INSA de Lyon, 2011. English. ⟨NNT : 2011ISAL0076⟩. ⟨tel-00701495⟩

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