Thermomechanical Analysis of Al-7075 to Predict Residual Stresses by Using 3D Finite Element Simulation

Abstract

Newer research and simulation tools are one of the advances in alloy manufacturing which allows prediction of final microstructure, residual stresses, and fatigue behavior before actual processing. Experimental procedures of measuring residual stresses using latest technology such as neutron X-ray diffraction techniques, ultrasonic technique, are tedious and expensive. In this paper, an approach is presented to predict residual stress behavior for block of different size as well as shape under thermomechanical loading for Al-7075 alloy block. Computer simulation was used as a tool in order to perform above task. Patran™ and Nastran™ finite element software was used. The predicted residual stresses are compared with experimental and simulated measurements. Outcomes signify that predicted values are in good accord with experimental and simulated measurements. It is found that material is experiencing compressive residual stresses at the surface and tensile residual stresses in the core due to thermal cycles and edge effect.