Incremental Formulation for the Prediction of Flow Stress and Microstructural Change in Hot Forming

1998 ◽  
Vol 120 (2) ◽  
pp. 316-322 ◽  
Author(s):  
J. Yanagimoto ◽  
K. Karhausen ◽  
A. J. Brand ◽  
R. Kopp
Keyword(s):  
Plastic Deformation ◽  
Flow Stress ◽  
Metal Forming ◽  
Mathematical Formulation ◽  
Microstructural Change ◽  
Hot Forming ◽  
Wide Range ◽  
Theoretical Predictions ◽  
Incremental Formulation ◽  
Formed Product

In metal forming, the workpieces are formed to the desired shapes or profiles. Especially in hot forming, the microstructure of workpiece changes during plastic deformation. Modern forming technologies allow to control the shape and the microstructure of formed product in a wide range and will gain increasing importance in future in the field of metal forming. In order to develop this forming technology which may be called “macroscopic microscopic materials processing”, theoretical predictions of plastic deformation as well as microstructural changes are indispensable. A new mathematical formulation to predict flow stress and microstructural change in hot forming will be presented in this paper. This model is based on an incremental formulation taking the dislocation density as a representative variable.

Analysis and Technology in Metal Forming

1989 ◽  
Author(s):  
Shiro Kobayashi ◽  
Soo-Ik Oh ◽  
Taylan Altan
Keyword(s):  
Heat Transfer ◽  
Plastic Deformation ◽  
Flow Stress ◽  
Velocity Field ◽  
Metal Forming ◽  
Metal Flow ◽  
Die Design ◽  
Flow Forming ◽  
Part Geometry ◽  
Formed Part

The design, control, and optimization of forming processes require (1) analytical knowledge regarding metal flow, stresses, and heat transfer, as well as (2) technological information related to lubrication, heating and cooling techniques, material handling, die design and manufacture, and forming equipment. The purpose of using analysis in metal forming is to investigate the mechanics of plastic deformation processes, with the following major objectives. • Establishing the kinematic relationships (shape, velocities, strain-rates, and strains) between the undeformed part (billet, blank, or preform) and the deformed part (product); i.e., predicting metal flow during the forming operation. This objective includes the prediction of temperatures and heat transfer, since these variables greatly influence local metal-flow conditions. • Establishing the limits of formability or producibility; i.e., determining whether it is possible to perform the forming operation without causing any surface or internal defects (cracks or folds) in the deforming material. • Predicting the stresses, the forces, and the energy necessary to carry out the forming operation. This information is necessary for tool design and for selecting the appropriate equipment, with adequate force and energy capabilities, to perform the forming operation. Thus, the mechanics of deformation provides the means for determining how the metal flows, how the desired geometry can be obtained by plastic deformation, and what the expected mechanical properties of the produced part are. For understanding the variables of a metal-forming process, it is best to consider the process as a system, as illustrated in Fig. 2.1 in Chap. 2. The interaction of most significant variables in metal forming are shown, in a simplified manner, in Fig. 3.1. It is seen that for a given billet or blank material and part geometry, the speed of deformation influences strain-rate and flow stress. Deformation speed, part geometry, and die temperature influence the temperature distribution in the formed part. Finally, flow stress, friction, and part geometry determine metal flow, forming load, and forming energy. In steady-state flow (kinematically), the velocity field remains unchanged, as is the case in the extrusion process; in nonsteadystate flow, the velocity field changes continuously with time, as is the case in upset forging.

scholarly journals Development of an integrated approach combining artificial neural network material based on modeling with finite element analysis of forming processes

2005 ◽  
Author(s):  
◽  
Brian Scott Kessler
Keyword(s):  
Finite Element ◽  
Flow Stress ◽  
Strain Rate ◽  
Strain Hardening ◽  
Integrated Approach ◽  
Hot Forming ◽  
Energy Materials ◽  
Softening Mechanism ◽  
Wide Range ◽  
Early Strain

The use of a finite element model for design and analysis of a metal forming processes is limited by the incorporated material model's ability to predict deformation behavior over a wide range of operating conditions. Conventionally generated rheological models prove deficient in several respects due to the difficulty in establishing complicated relations between many parameters. More recently, artificial neural networks (ANN) have been suggested as an effective means to overcome these difficulties. To this end, a robust ANN with the ability to determine flow stresses based on strain, strain rate, and temperature is developed and linked with finite element based simulation model. Comparisons of this novel method with conventional means are carried out to demonstrate the advantages of this approach as applied to industrial applications. The flow stress curves generated using the developed ANN method for 6061 alumimum show the typical behavior of high stacking fault energy materials, where the controlling softening mechanism is dynamic recovery (early strain hardening followed by a smooth transition to a plateau of stress). In contrast, the flow stress behavior of nickel aluminide exhibits the typical behavior of low stacking fault energy materials, where the controlling softening mechanism in hot working is dynamic recrystallization (early strain hardening to a peak stress followed by drop and oscillation of the flow stress about a steady average value). A thermo-mechanical coupled finite element method (FEM) using the commercial code ABAQUS as a platform for development is introduced to simulate hot forming processes. The FEM model is integrated with the developed ANN material based model in order to account for the effects of strain, strain rate, and temperature variations within the material during hot-forming. An industrial case study involves hot forging of an aftermarket automotive wheel made out of 6061 aluminum is used to evaluate the effectiveness of the integrated approach. The load-displacement curves predicted by the developed virtual model are in good agreement with the experimental observations of an industrial forging process. The developed approach and knowledge gained from the present work, has a wide range of application in general, and is not limited to hot forming of the investigated materials. The new approach is applicable to all hot forming processes of different alloy systems.

QCD at Fixed Order: Processes

2018 ◽  
Author(s):  
John Campbell ◽  
Joey Huston ◽  
Frank Krauss
Keyword(s):  
Hadron Collider ◽  
Detailed Comparison ◽  
Theoretical Description ◽  
Higgs Bosons ◽  
Final States ◽  
Collider Physics ◽  
Wide Range ◽  
Theoretical Predictions ◽  
Fixed Order ◽  
The Subject

At the core of any theoretical description of hadron collider physics is a fixed-order perturbative treatment of a hard scattering process. This chapter is devoted to a survey of fixed-order predictions for a wide range of Standard Model processes. These range from high cross-section processes such as jet production to much more elusive reactions, such as the production of Higgs bosons. Process by process, these sections illustrate how the techniques developed in Chapter 3 are applied to more complex final states and provide a summary of the fixed-order state-of-the-art. In each case, key theoretical predictions and ideas are identified that will be the subject of a detailed comparison with data in Chapters 8 and 9.

scholarly journals A Physical-Based Plane Stress Constitutive Model for High Strength AA7075 under Hot Forming Conditions

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 314
Author(s):  
Fulong Chen ◽  
Haitao Qu ◽  
Wei Wu ◽  
Jing-Hua Zheng ◽  
Shuguang Qu ◽  
...  
Keyword(s):  
Grain Size ◽  
Aluminum Alloy ◽  
Plane Stress ◽  
Metal Forming ◽  
Electron Backscatter Diffraction ◽  
High Strength ◽  
Material Model ◽  
Hot Forming ◽  
Industrial Processing ◽  
Average Grain Size

Physicallybased constitutive equations are increasingly used for finite element simulations of metal forming processes due to the robust capability of modelling of underlying microstructure evolutions. However, one of thelimitations of current models is the lack of practical validation using real microstructure data due to the difficulties in achieving statistically meaningful data at a sufficiently large microstructure scale. Particularly, dislocation density and grain size governing the hardening in sheet deformation are of vital importance and need to be precisely quantified. In this paper, a set of dislocation mechanics-based plane stress material model is constructed for hot forming aluminum alloy. This material model is applied to high strength 7075 aluminum alloy for the prediction of the flow behaviorsconditioned at 300–400 °C with various strain rates. Additionally, an electron backscatter diffraction (EBSD) technique was applied to examine the average grain size and geometrical necessary dislocation (GND) density evolutions, enabling both macro- and micro- characteristics to be successfully predicted. In addition, to simulate the experienced plane stress states in sheet metal forming, the calibrated model is further extended to a plane stress stateto accuratelypredict the forming limits under hot conditions.The comprehensively calibrated material model could be used for guidinga better selection of industrial processing parameters and designing process windows, taking into account both the formed shape as well as post formed microstructure and, hence, properties.

scholarly journals The plastic deformation of iron and the formation of Neumann lines

1925 ◽  
Vol 108 (745) ◽  
pp. 231-231
Keyword(s):  
Plastic Deformation ◽  
Pure Iron ◽  
Crystal Surfaces ◽  
Size And Shape ◽  
Slip Bands ◽  
Wide Range ◽  
Moderate Rate ◽  
Rapid Deformation

The object of the investigation described in the present paper was to ascertain the manner in which wide variations in speed affect the mechanism of deformation in plastic metals. Iron was selected as the first metal for experiment, mainly because it is known that rapid deformation produced by shock is accompanied in this metal by special features, known as Neumann lines or lamellæ. When a piece of nearly pure iron, of suitable size and shape, with one face polished and etched, is subsequently subjected to plastic deformation at a moderate rate, the crystal surfaces, when examined under the microscope after deformation, show the well-known appearance of slip bands (1). The present experiments were undertaken in the first instance to ascertain whether the character, number and appearance of such slip bands would be appreciably affected by varying the rate of deformation over a wide range. For the sake of convenience, deformation by compression has been employed, the metal being used in the form of small rectangular prisms, measuring in some instances 0.44 inch by 0.44 inch in section by 0.7 inch in height.

Formability of Explosive Welded Mg/Al Bimetallic Bar

2016 ◽  
Vol 716 ◽  
pp. 114-120 ◽  
Author(s):  
Sebastian Mróz ◽  
Piotr Szota ◽  
Teresa Bajor ◽  
Andrzej Stefanik
Keyword(s):  
Plastic Deformation ◽  
Strain Rate ◽  
Process Parameters ◽  
Metal Forming ◽  
Explosive Welding ◽  
Physical Modelling ◽  
Main Process ◽  
Compression Tests ◽  
Welding Method

The paper presents the results of physical modelling of the plastic deformation of the Mg/Al bimetallic specimens using the Gleeble 3800 simulator. The plastic deformation of Mg/Al bimetal specimens characterized by the diameter to thickness ratio equal to 1 was tested in compression tests. The aim of this work was determination of the range of parameters as temperature and strain rate that mainly influence on the plastic deformation of Mg/Al bars during metal forming processes. The tests were carried out for temperature range from 300 to 400°C for different strain rate values. The stock was round 22.5 mm-diameter with an Al layer share of 28% Mg/Al bars that had been produced using the explosive welding method. Based on the analysis of the obtained testing results it has been found that one of the main process parameters influencing the plastic deformation the bimetal components is the initial stock temperature and strain rate values.

Effect of Hydrogen on the Development of Superplastic Deformation in the Submicrocrystalline Ti–6Al–4V Alloy

2016 ◽  
Vol 838-839 ◽  
pp. 344-349 ◽  
Author(s):  
Galina P. Grabovetskaya ◽  
Ekaterina N. Stepanova ◽  
Ilya V. Ratochka ◽  
I.P. Mishin ◽  
Olga V. Zabudchenko
Keyword(s):  
Solid Solution ◽  
Plastic Deformation ◽  
Flow Stress ◽  
Superplastic Deformation ◽  
Deformation Localization ◽  
Solid Solution Strengthening ◽  
Solution Strengthening ◽  
Hydrogenation Effect

Hydrogenation effect on the development of superplastic deformation in the submicrocrystalline Ti–6Al–4V alloy at temperatures (0.4–0.5)Тmelt is investigated. Hydrogenation of the submicrocrystalline Ti–6Al–4V alloy to 0.26 mass% during superplastic deformation is found to result in solid solution strengthening, plastic deformation localization, and as a consequence, decrease of the deformation to failure. Possible reasons for the decrease of the flow stress and increase of the deformation to failure in the submicrocrystalline Ti–6Al–4V–0.26H alloy during deformation under conditions of superplasticity and simultaneous hydrogen degassing from the alloy are discussed.

SIMULATION OF AN AXISYMMETRIC RISING BUBBLE BY A MULTIPLE RELAXATION TIME LATTICE BOLTZMANN METHOD

2009 ◽  
Vol 23 (24) ◽  
pp. 4907-4932 ◽  
Author(s):  
ABBAS FAKHARI ◽  
MOHAMMAD HASSAN RAHIMIAN
Keyword(s):  
Free Surface ◽  
Lattice Boltzmann Method ◽  
Lattice Boltzmann ◽  
Rise Velocity ◽  
Rising Bubble ◽  
Wide Range ◽  
Theoretical Predictions ◽  
Multiple Relaxation Time ◽  
Bubble Rising ◽  
Boltzmann Method

In this paper, the lattice Boltzmann method is employed to simulate buoyancy-driven motion of a single bubble. First, an axisymmetric bubble motion under buoyancy force in an enclosed duct is investigated for some range of Eötvös number and a wide range of Archimedes and Morton numbers. Numerical results are compared with experimental data and theoretical predictions, and satisfactory agreement is shown. It is seen that increase of Eötvös or Archimedes number increases the rate of deformation of the bubble. At a high enough Archimedes value and low Morton numbers breakup of the bubble is observed. Then, a bubble rising and finally bursting at a free surface is simulated. It is seen that at higher Archimedes numbers the rise velocity of the bubble is greater and the center of the free interface rises further. On the other hand, at high Eötvös values the bubble deforms more and becomes more stretched in the radial direction, which in turn results in lower rise velocity and, hence, lower elevations for the center of the free surface.

Microstructural Change of Beta Type Titanium Alloy by Intense Plastic Deformation

2006 ◽  
Vol 503-504 ◽  
pp. 705-710 ◽  
Author(s):  
Goroh Itoh ◽  
Hisashi Hasegawa ◽  
Tsing Zhou ◽  
Yoshinobu Motohashi ◽  
Mitsuo Niinomi
Keyword(s):  
Plastic Deformation ◽  
Work Hardening ◽  
Static Recrystallization ◽  
True Strain ◽  
Microstructural Change ◽  
Intense Plastic Deformation ◽  
Rolled Plate ◽  
Al Alloy ◽  
Hot Rolled ◽  
Zr Alloy

Usual static recrystallization treatment and a method to provide intense plastic deformation, ARB namely Accumulative Roll-Bonding, have been applied to two beta type titanium alloys, i.e. Ti-29Nb-13Ta-4.6Zr and Ti-15V-3Cr-3Sn-3Al. Microstructural change as well as work-hardening behavior was examined as a function of plastic strain. Both the work-hardening rate and the hardness at the initial as-hot-rolled state were smaller in the Ti-Nb-Ta-Zr alloy than in the Ti-V-Cr-Sn-Al alloy. Recrystallized grains of 14μm in size were obtained by the usual static recrystallization treatment, which was significantly smaller than that of the starting as-hot-rolled plate of 38μm. No significant change other than flattening and elongating of the original grains was found in the optical microscopic scale. It was revealed, however, from a TEM observation combined with selected area diffraction technique that geometric dynamic recrystallization occurred in the Ti-Nb-Ta-Zr alloy deformed at room temperature by a true strain of 5, resulting in an ultra-fine-grained microstructure where the grain size was roughly estimated to be about 100nm.

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