Numerical Modelling of the Powder Metallurgical Manufacturing Chain of High Strength Sintered Gears

AbstractThis paper presents a digital model for the powder metallurgical (PM) production chain of high-performance sintered gears based on an integrated computational materials engineering (ICME) platform. Discrete and finite element methods (DEM and FEM) were combined to describe the macroscopic material response to the thermomechanical loads and process conditions during the entire production process. The microstructural evolution during the sintering process was predicted on the meso-scale using a Monte-Carlo Model. The effective elastic properties were determined by a homogenization method based on modelling a representative volume element (RVE). The results were subsequently used for the FE modelling of the heat treatment process. Through the development of multi-scale models, it was possible obtain characteristics of the microstructural features. The predicted hardness and residual stress distributions allowed the calculation of the tooth root load bearing capacity of the heat-treated sintered gears.

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A Digital Twin of the Powder Metallurgical Manufacturing Chain of High Strength Sintered Gears

10.21203/rs.3.rs-95131/v1 ◽

2020 ◽

Author(s):

Ali Rajaei ◽

Yuanbin Deng ◽

Oliver Schenk ◽

Soheil Rooein ◽

Alexander Bezold ◽

...

Keyword(s):

High Performance ◽

Monte Carlo Model ◽

High Strength ◽

Homogenization Method ◽

Process Conditions ◽

Fe Modelling ◽

Production Chain ◽

Digital Twin ◽

Computational Materials ◽

The One

Abstract This paper presents a digital twin of the powder metallurgical (PM) production chain of high-performance sintered gears based on an integrated computational materials engineering (ICME) platform. Discrete and finite element methods (DEM and FEM) were combined to describe the macroscopic material response to the thermomechanical loads and process conditions during the entire production process. The microstructural evolution during the sintering process was predicted on then meso-scale using a Monte-Carlo Model. The effective elastic properties were determined by a homogenization method based on modelling a representative volume element (RVE). The results were subsequently used for the FE modelling of the heat treatment process. Through the development of multi-scale models, it was possible on the one hand to obtain characteristics of the microstructural features and on the other hand the predicted hardness and residual stress distributions allow the calculation of the tooth root load bearing capacity of the heat-treated sintered gears.

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The Innovative Design of Suspension Cast Components of Vehicles Made from High-Strength AlZnMgCu Alloy Resistant to an IED Type Threat

Solid State Phenomena ◽

10.4028/www.scientific.net/ssp.223.181 ◽

2014 ◽

Vol 223 ◽

pp. 181-190

Author(s):

Robert Żuczek ◽

Stanisław Pysz ◽

Piotr Sprawka ◽

Tomasz Muszyński

Keyword(s):

High Performance ◽

High Strength ◽

Industrial Applications ◽

Design Development ◽

Materials Engineering ◽

Critical Areas ◽

Integrated Computational Materials Engineering ◽

Lower Control Arm ◽

Computational Materials ◽

New Research

The new research trends are moving away from research works that are not directly connected with industrial applications. The Integrated Computational Materials Engineering (ICME) is an excellent example of the relationship between scientific research and the industrial sector.As an example of the design development of construction of a suspension component, an overview of the changes of a welded part replaced with cast component is presented. The identification of boundary conditions and forces operating on the nodes of the suspension element allowed determining the critical areas in the existing welded construction. Then the new design of casting for high performance applications was developed. Analysis of the kinematics of the suspension components also revealed the need for changes in the design of the mounting points of the suspension components to reduce the maximum values of forces and enforced moments. As a result of successive stages of the topology optimization of analysed cast, control arms with significantly lower values of maximum stresses were obtained. The material conversion of welded part with high strength AlZnMgCu aluminium alloy allowed the reduction of the weight by 25% for the lower control arm and 30% for upper control arm.

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