Crack propagation

1. INVESTIGATION OF CRACK
PROPAGATION IN Al 2014 INGOT
SUBJECTED TO WIRE CUTTING
Project Review-2
Team A11
S.ROSHINI- 2451-18-736-010
S.JHATI – 2451-18-736-017
Under the guidance of
Dr. Suri Srinivas
M.Tech., Ph.D., MISTE, MIE, C. Engg.(I)
Assistant Professor
Department of Mechanical Engineering
Maturi Venkata Subba Rao (MVSR) Engineering College (A)

2. ● This project deals with the effects of wire EDM
conditions on generation of residual stresses in
machining of aluminum 2014 T6 alloy.
● Aim of the project is to investigate the crack
growth.
● Microscopic examination and testing of forged,
heat treated ingot.
ABSTRACT

3. SCOPE OF WORK
● Literature survey
● Selection of Material
● Studying different types of Aluminum alloys
● Examine factors affecting residual stresses
● Heat treatment conditions and effects
● Designing the Model in solidworks
● Quality control check, Tensile testing, Scanning Electron Microscopy
● Drawing and discussing the results
● Compare between Simulation and experimental analysis

4. LITERATURE SURVEY
PUJARI SRINIVAS
RAO,
KONNA RAMJI,
BEELA
SATYANARAYAN
● Analysis on the residual
stresses developed during
wire cutting in aluminum
alloys
● Max residual stress observed
is 405.6 Mpa
ELSEVIER JOURNAL
(ALEXANDRIA
UNIVERSITY)
2018
B.V.R.RAVI KUMAR
A.SUDHEER RAJA
● Experimental behavior of
tensile properties of Al-2014
alloy.
● Using FSW and GTAW
joining processes
IJEAT JOURNAL
2020
YAHAYA
A.A.A.MAJID
● Review on aluminum alloys
application and methods
employed
ACADEMIA
PUBLISHING
2013

5. Investigation the crack propagation in al-
2014 alloy material under wire cutting
EDM operation to conclude the cause
and remedy for this failure in the
material.
PROBLEM DEFINITION

6. SELECTION OF MATERIAL
AL-2014 ALLOY
● 2XXX alloy with Cu as its major element
● Strongest available aluminium alloys
● High hardness
● Commonly extruded and forged
● Industry conventional designation - 14S

7. COMPOSITION OF MATERIAL
AL-2014: (presently used material have 4.4% copper)
ELEMENT COMPOSITION
ALUMINIUM 93.4 -95% max
CHROMIUM 0.1% max
COPPER 3.9- 4.5% max
IRON 0.7% max
MANGANESE 0.4 - 1.2%max
SILICON 0.5-1.2% max
TITANIUM+ZINC 0.2% max

8. PROCESSING PROPERTIES
ANNEALING
TEMPERATURE
413 degrees AA2014
SOLUTION TREATMENT 502 degrees AA2014
AGING TEMPERATURE 160 degrees Sheet,plate,wire,rod,bar,shapes,t
ube,
18hr at temperature
AGING TEMPERATURE 171 degrees Forgings,10hr at temperature

9. CRACK FORMATION DUE TO RESIDUAL STRESSES
CONDITION FOR CRACK FORMATION
Heat treatment
Fatigue or Creep
Stress ,corrosion
Cooling , Solidification

10. KEY TERMS
● T6 condition
● SEM
● Wire EDM
● Residual stresses
● Aluminum

11. Quality check and
acquiring report
from QC dept
Tensile testing,
Micro-structure
micro-hardness ,
SEM
Analysis of tests
and internal
structure
Creating a
numerical model
for data
comparison
Discussion of
results and finding
effective way to
reduce cracks
An ingot is made
of Al-2014
material, cutting
of tensile
specimens
TIMELINE

12. OUR WORKS
1. Modelling the tensile specimen and ingot
2. Simulation of the tensile specimen and
comparing to experiment.
3. Tensile specimen cutting and testing
4. Quality check and Numerical modelling

13. SPECIMEN MODEL
AA2014 TENSILE
TEST SPECIMEN.
GAUGE LENGTH -
32mm
RADIUS OF FILLET-
6mm
FLAT PLATE
SPECIMEN

14. QUALITY CONTROL REPORT
S1 S2 S3
WIDTH 6.27 6.27 6.27
THICKNESS 4.04 4.09 3.96
RADIUS OK OK OK
OVERALL
LENGTH
100.06 100.01 100.01
GRIP SECTION 30.13, 30.17 30.08, 30.15 30.06,30.04
WIDTH 10.05 10.03 10.05

15. TRIAL EXPERIMENTAL INVESTIGATIONS:
(from journals)
ANOVA method

17. Taguchi method

19. REGRESSION
ANALYSIS

20. SPECIMEN ID PEAK STRESS
(MPa)
PEAK LOAD
(kN)
0.2% OFFSET
YIELD STRESS
TTS_AA2014_S1 472.622 12.023 413.857
TTS_AA2014_S2 491.434 12.602 421.619
TTS_AA2014_S3 495.322 12.194 432.016
RESULTS(expt.)

22. Stress analysis in S1 simulation

23. Deformation due to load

24. RESULTS and DISCUSSIONS
1. Ultimate Tensile stresses - 476.94 MPa
2. Elongation - 7.04%
3. Maximum loading observed - 12622N
4. ANOVA confidence level - 94.86%
5. Maximum residual stress - 405.6 Mpa
6. S/N ratio analysis shows the optimal
parameter

25. THANK YOU
Any queries???