Effect of Cusp Size, Depth and Direction on Stress Concentration

Md Shams E Tabriz, Simon Barrans

Research output: Contribution to journalArticle

Abstract

Recently multi-axial machining technology has improved significantly. It has become a widely accepted method of manufacturing components with complex, free form surfaces. Solid billet materials with negligible internal defects are used in this process. This provides increased durability and fatigue life over equivalent cast components. However, multi-axial machining leaves cusps as machining marks. The combination of tool size and step-over generates cusps with different depths and widths. Even though the cusps add extra material on top of the nominal surface, the Finite Element Analysis simulations presented in this paper show that the maximum stress generated within the cusps can be greater than that predicted from the cusp-free geometry. These stress concentrations generated by cusps can reduce the fatigue life and durability of a machined component.

In this paper a full factorial analysis of the effect of tool size, cusp width/step-over and cusp direction has been conducted. The analysis uses five different levels of tool size and cusps width and four levels of cusp direction. The results can be used to determine a tool size, cusp width and cusp direction combination with minimum spurious stress raising effect.
Original languageEnglish
Pages (from-to)88-93
Number of pages6
JournalSAE International Journal of Materials and Manufacturing
Volume6
Issue number2
Early online date1 Oct 2017
Publication statusPublished - 1 Apr 2018

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Stress concentration
Machining
Durability
Fatigue of materials
Finite element method
Defects
Geometry

Cite this

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Effect of Cusp Size, Depth and Direction on Stress Concentration. / Tabriz, Md Shams E; Barrans, Simon.

In: SAE International Journal of Materials and Manufacturing, Vol. 6, No. 2, 01.04.2018, p. 88-93.

Research output: Contribution to journalArticle

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