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<p>Medium-carbon steel thin-walled spherical shells are prone to non-uniform residual stresses during hot forging, cooling, and heat treatment, which significantly affect their mechanical properties and service life. To accurately predict the evolution of residual stresses, this study has developed a thermo–elasto–plastic constitutive model based on phase transformation theory. The model describes temperature-induced microstructural transformations and the corresponding mechanical behavior of medium-carbon steel during processing. It couples the USDFLD, UEXPAN, UMAT, and HETVAL subroutines to account for thermal, transformation, and transformation-induced plastic strains. Abaqus was used to transfer stress, temperature, and deformation data from preceding process steps to subsequent analyses, which enabled accurate tracking of the spherical shell manufacturing process. The approach facilitates data transfer and coupled computation throughout the production sequence. Experimental results indicate that the model can accurately predict the evolution of the residual stress field in medium-carbon steel during hot forging and heat treatment.</p>

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Prediction of Residual Stress Evolution in Medium-Carbon Steel Thin-Walled Spherical Shells During Multi-Stage Manufacturing

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Yupeng Wu,
  • Quanwei Yang,
  • Zhaocheng Wei,
  • Yuxin Fang,
  • Dong Wang

摘要

Medium-carbon steel thin-walled spherical shells are prone to non-uniform residual stresses during hot forging, cooling, and heat treatment, which significantly affect their mechanical properties and service life. To accurately predict the evolution of residual stresses, this study has developed a thermo–elasto–plastic constitutive model based on phase transformation theory. The model describes temperature-induced microstructural transformations and the corresponding mechanical behavior of medium-carbon steel during processing. It couples the USDFLD, UEXPAN, UMAT, and HETVAL subroutines to account for thermal, transformation, and transformation-induced plastic strains. Abaqus was used to transfer stress, temperature, and deformation data from preceding process steps to subsequent analyses, which enabled accurate tracking of the spherical shell manufacturing process. The approach facilitates data transfer and coupled computation throughout the production sequence. Experimental results indicate that the model can accurately predict the evolution of the residual stress field in medium-carbon steel during hot forging and heat treatment.