Inverse Thermo-Mechanical Processing (ITMP) Design of a Steel Rod During Hot Rolling Process

2019 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Pranav Mohan ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Hot Rolling ◽  
Design Method ◽  
Integrated Design ◽  
Computational Design ◽  
Rolling Process ◽  
Manufacturing Processes ◽  
Mechanical Processing ◽  
Design Exploration ◽  
And Performance ◽  
Decision Based Design

Abstract The production of steel products involves a series of manufacturing processes. The material Thermo-Mechanical Processing (TMP) history at each process affects the final properties and performances of the product. Experiments and plant trials to predict these properties and performance of steel products are expensive and time consuming. This has resulted in the need for computational design methods and tools that support a human designer in realizing such complex systems involving the material, product and manufacturing processes from a simulation-based design perspective. In this paper, we present a Goal-oriented Inverse Design method to achieve the integrated design exploration of materials, products and manufacturing processes. The key functionality offered is the capability to carry out a microstructure-mediated design satisficing specific processing requirements and performance goals of the product. Given models to establish the information flow chain, a designer can use the method for the decision-based design exploration of material microstructure and processing paths to realize products in a manufacturing process chain. The efficacy of the method is tested using an industry-inspired hot rolling problem to inversely design the thermo-mechanical processing of a steel rod. The focus here is the method and associated design constructs which are generic and support the formulation and decision-based design of similar problems involving materials, products and associated manufacturing processes.

An Inverse, Decision-Based Design Method for Integrated Design Exploration of Materials, Products, and Manufacturing Processes

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Vignesh Rangaraj ◽  
B. P. Gautham ◽  
Amarendra Kumar Singh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Design Method ◽  
Integrated Design ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Structure Property ◽  
Horizontal Integration ◽  
Design Exploration ◽  
Rod Rolling ◽  
Manufacturing Process Chain ◽  
Decision Based Design

A material's design revolution is underway with a focus to design the material microstructure and processing paths to achieve certain performance requirements of products. A host of manufacturing processes are involved in producing a product. The processing carried out in each process influences its final properties. To couple the material processing-structure-property-performance (PSPP) spaces, models of specific manufacturing processes must be enhanced and integrated using multiscale modeling techniques (vertical integration) and then the input and output of the various manufacturing processes must be integrated to facilitate the flow of information from one process to another (horizontal integration). Together vertical and horizontal integration allows for the decision-based design exploration of the manufacturing process chain in an inverse manner to realize the end product. In this paper, we present an inverse method to achieve the integrated design exploration of materials, products, and manufacturing processes through the vertical and horizontal integration of models. The method is supported by the concept exploration framework (CEF) to systematically explore design alternatives and generate satisficing design solutions. The efficacy of the method is illustrated for a hot rod rolling (HRR) and cooling process chain problem by exploring the processing paths and microstructure in an inverse manner to produce a rod with specific mechanical properties. The proposed method and the exploration framework are generic and support the integrated decision-based design exploration of a process chain to realize an end product by tailoring material microstructures and processing paths.

A Goal-Oriented, Inverse Decision-Based Design Method to Achieve the Vertical and Horizontal Integration of Models in a Hot Rod Rolling Process Chain

2017 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Vignesh Rangaraj ◽  
B. P. Gautham ◽  
Amarendra Kumar Singh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Design Method ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Structure Property ◽  
Horizontal Integration ◽  
Design Exploration ◽  
Unit Operations ◽  
Manufacturing Process Chain ◽  
Decision Based Design

Reducing the manufacturing and marketing time of products by means of integrated simulation-based design and development of the material, product, and the associated manufacturing processes is the need of the hour for industry. This requires the design of materials to targeted performance goals through bottom-up and top-down modeling and simulation practices that enables handshakes between modelers and designers along the entire product realization process. Manufacturing a product involves a host of unit operations and the final properties of the manufactured product depends on the processing steps carried out at each of these unit operations. In order to effectively couple the material processing-structure-property-performance spaces, there needs to be an interplay of the systems-based design of materials with enhancement of models of various unit operations through multiscale modeling methodologies and integration of these models at different length scales (vertical integration). This ensures the flow of information from one unit operation to another thereby establishing the integration of manufacturing processes (horizontal integration). Together these types of integration will support the decision-based design of the manufacturing process chain so as to realize the end product. In this paper, we present a goal-oriented, inverse decision-based design method to achieve the vertical and horizontal integration of models for the hot rolling and cooling stages of the steel manufacturing process chain for the production of a rod with defined properties. The primary mathematical construct used for the method presented is the compromise Decision Support Problem (cDSP) supported by the proposed Concept Exploration Framework (CEF) to generate satisficing solutions under uncertainty. The efficacy of the method is illustrated by exploring the design space for the microstructure after cooling that satisfies the requirements identified by the end mechanical properties of the product. The design decisions made are then communicated in an inverse manner to carry out the design exploration of the cooling stage to identify the design set points for cooling that satisfies the new target microstructure requirements identified. Specific requirements such as managing the banded microstructure to minimize distortion in forged gear blanks are considered in the problem. The proposed method is generic and we plan to extend the work by carrying out the integrated decision-based design exploration of rolling and reheating stages that precede to realize the end product.

Robust Concept Exploration of Materials, Products and Associated Manufacturing Processes

2018 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Pranav Mohan ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Robust Design ◽  
Design Method ◽  
Integrated Design ◽  
Manufacturing Processes ◽  
Type I ◽  
Process Chain ◽  
Process Chains ◽  
Concept Exploration ◽  
Decision Based Design ◽  
Noise Factors

In this paper, we present robust concept exploration using a goal-oriented, inverse decision-based design method to carry out the integrated design of material, product and associated manufacturing processes by managing the uncertainty involved. The uncertainty in complex material and product systems is derived from many sources and we classify robust design based on these sources — uncertainty in noise factors (Type I robust design); uncertainty in design variables or control factors (Type II robust design); uncertainty in function relationship between control/noise and response (Type III robust design); and propagation and potential amplification of uncertainty in a process chain (Type I to III robust designs across process chains). In this paper, we introduce a variation to the existing goal-oriented inverse decision-based design method to bring in robustness for multiple conflicting goals from the stand-point of Type I to III robust design across process chains. The variation embodies the introduction of specific robust design goals and constraints anchored in the mathematical constructs of error margin indices and design capability indices to determine “satisficing robust design” specifications for given performance requirement ranges using the goal-oriented, inverse design method. The design of a hot rolling process chain for the production of a rod is used as an example.

Analysis of Microstructures and XRD of a Gradient Boron Alloyed Composite Material

2013 ◽  
Vol 680 ◽  
pp. 113-118
Author(s):  
Guo Liang Xie ◽  
Qiang Song Wang ◽  
Xu Jun Mi ◽  
Bai Qing Xiong ◽  
Jing Tao Han ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Composite Material ◽  
Hot Rolling ◽  
Rolling Process ◽  
The Core ◽  
The Matrix ◽  
New Type ◽  
And Performance ◽  
Hot Rolled ◽  
Stainless Steel Coatings

A new type of gradient boron alloyed composite material, containing boron alloyed core layers and stainless steel coatings around the core, were designed and prepared by composite casting and hot rolling. The evolution of microstructures, phases and precipitations, as well as their influence on hot rolling process and performance are investigated. A mixture of austenitic matrix and uniformly distributed borides are obtained in the hot rolled stainless steel with 2-2.5 % boron, while massive borides are in the length of 80-120 μm together with micro gaps at the interface between the borides, and the matrix is remained after hot rolling for the core layers with higher boron contents. Hot deformation would be hindered since more precipitations of these orthorhombic or tetragonal phases occur with an increase of the boron concentration in the core layers.

Exploration of Solution Space to Study Thermo-Mechanical Behavior of AA5083 Al-Alloy During Hot Rolling Process

2017 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Rishabh Shukla ◽  
Surya Ardham ◽  
Chung-Hyun Goh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Process Parameters ◽  
Hot Rolling ◽  
Design Method ◽  
Solution Space ◽  
Rolling Process ◽  
Al Alloy ◽  
Aa5083 Alloy ◽  
Simulation Based Design ◽  
Process Operation ◽  
Set Based Design

A method is proposed to explore the solution space of a metallurgical process with an aim to foster material innovation through simulation based design. The efficacy of the method is demonstrated in the context of hot rolling of the AA5083 alloy. The set-based design approach is employed to predict the process parameters of rolling operation for a given set of specified requirements. Critical process parameters such as strain rate, temperature, heat transfer coefficient and strip width are only considered in the design study. Ternary plots are constructed and utilized to explore the solution space obtained and thereby identifying feasible regions of process operation wherein the specified requirements are satisfied. Since plant data is not available for the study, Finite-element (FE) analysis is carried out as a means to validate the results obtained using aforesaid design method.

Hot Rolling Process Simulation: Application to UIC-60 Rail Rolling

2010 ◽  
Vol 3 (1) ◽  
pp. 65-71
Author(s):  
Armindo Guerrero ◽  
Javier Belzunce ◽  
Covadonga Betegon ◽  
Julio Jorge ◽  
Francisco J. Vigil
Keyword(s):  
Hot Rolling ◽  
Process Simulation ◽  
Rolling Process ◽  
Hot Rolling Process

scholarly journals Shaping Microstructure and Mechanical Properties of High-Carbon Bainitic Steel in Hot-Rolling and Long-Term Low-Temperature Annealing

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 384
Author(s):  
Tomasz Dembiczak ◽  
Marcin Knapiński
Keyword(s):  
Mathematical Models ◽  
Hot Rolling ◽  
Constitutive Equations ◽  
Rolling Process ◽  
Bainitic Steel ◽  
Compression Tests ◽  
High Carbon ◽  
Bainite Steel ◽  
Dilatometric Studies

Based on the research results, coefficients in constitutive equations, describing the kinetics of dynamic, meta-dynamic, and static recrystallization in high-carbon bainitic steel during hot deformation were determined. The developed mathematical model takes into account the dependence of the changing kinetics in the structural size of the preliminary austenite grains, the value of strain, strain rate, temperature, and time. Physical simulations were carried out on rectangular specimens. Compression tests with a flat state of deformation were carried out using a Gleeble 3800. Based on dilatometric studies, coefficients were determined in constitutive equations, describing the grain growth of the austenite of high-carbon bainite steel under isothermal annealing conditions. The aim of the research was to verify the developed mathematical models in semi-industrial conditions during the hot-rolling process of high-carbon bainite steel. Analysis of the semi-industrial studies of the hot-rolling and long-term annealing process confirmed the correctness of the predicted mathematical models describing the microstructure evolution.

scholarly journals 3D-FEM Simulation of Hot Rolling Process and Characterization of the Resultant Microstructure of a Light-Weight Mn Steel

Crystals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 569
Author(s):  
Ana Claudia González-Castillo ◽  
José de Jesús Cruz-Rivera ◽  
Mitsuo Osvaldo Ramos-Azpeitia ◽  
Pedro Garnica-González ◽  
Carlos Gamaliel Garay-Reyes ◽  
...  
Keyword(s):  
Hot Rolling ◽  
Thermomechanical Processing ◽  
Computational Simulation ◽  
Effective Strain ◽  
Fem Simulation ◽  
Rolling Process ◽  
3D Fem ◽  
Hot Rolling Process ◽  
Mn Steel

Computational simulation has become more important in the design of thermomechanical processing since it allows the optimization of associated parameters such as temperature, stresses, strains and phase transformations. This work presents the results of the three-dimensional Finite Element Method (FEM) simulation of the hot rolling process of a medium Mn steel using DEFORM-3D software. Temperature and effective strain distribution in the surface and center of the sheet were analyzed for different rolling passes; also the change in damage factor was evaluated. According to the hot rolling simulation results, experimental hot rolling parameters were established in order to obtain the desired microstructure avoiding the presence of ferrite precipitation during the process. The microstructural characterization of the hot rolled steel was carried out using optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). It was found that the phases present in the steel after hot rolling are austenite and α′-martensite. Additionally, to understand the mechanical behavior, tensile tests were performed and concluded that this new steel can be catalogued in the third automotive generation.

Sign in / Sign up

Export Citation Format

Share Document