scholarly journals Sustainable Manufacturing of Ultra-Fine Aluminium Alloy 6101 Wires Using Controlled High Levels of Mechanical Strain And Finite Element Modeling

2022 ◽  
Author(s):  
Serafino Caruso ◽  
Luigino Filice
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Severe Plastic Deformation ◽  
Aluminium Alloy ◽  
Manufacturing Process ◽  
Industry 4.0 ◽  
Mechanical Strain ◽  
Sustainable Manufacturing ◽  
Smart Manufacturing ◽  
Fe Model

Abstract The evolution of grain size and component mechanical behaviour are fundamental aspects to analyse and control when manufacturing processes are considered. In this context, severe plastic deformation (SPD) processes, in which a high shear strain is imposed on the material, are recognized as the main techniques to achieve microstructural changes and material strengthening by the recrystallization, attracting both academic and industrial investigation activities. At the same time, nowadays, sustainable manufacturing design is one of the main responsibilities of the researchers looking at UN2030 agenda and the modern industrial paradigms. In this paper a new severe SPD process is proposed with the aim to steer manufacturing to fourth industrial revolution using some of Industry 4.0 pillars. In particular, additive manufacturing (AM) and numerical simulations were setup as controlling and monitoring techniques in manufacturing process of wires.Strengthening effect (yield and ultimate tensile strength, plasticity and hardness) and microstructural evolution (continuous dynamic recrystallization -CDRX-) due to severe plastic deformation were experimentally analysed and numerically investigated by an innovative finite element (FE) model able to validate the effectiveness of a properly modified process for ultra-fine aluminium alloy AA6101 wires production designed with the aim to avoid any post manufacturing costly thermal treatment.The study provides an accurate experimental study and numerical prediction of the thermo-mechanical and microstructural phenomena that occur during an advanced large plastic deformation process; it shows how the combination of smart manufacturing and simulations control represents the key to renew the traditional manufacturing methods in the perspective of the Industry 4.0, connecting and integrating the manufacturing process for the industrial evolution in production.

scholarly journals Sustainable manufacturing of ultra-fine aluminium alloy 6101 wires using controlled high levels of mechanical strain and finite element modeling

2021 ◽  
Author(s):  
Serafino Caruso ◽  
Luigino Filice
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Severe Plastic Deformation ◽  
Aluminium Alloy ◽  
Manufacturing Process ◽  
Industry 4.0 ◽  
Sustainable Manufacturing ◽  
Smart Manufacturing ◽  
Fe Model ◽  
Strengthening Effect

AbstractThe evolution of grain size and component mechanical behaviour are fundamental aspects to analyse and control when manufacturing processes are considered. In this context, severe plastic deformation (SPD) processes, in which a high shear strain is imposed on the material, are recognized as the main techniques to achieve microstructural changes and material strengthening by the recrystallization, attracting both academic and industrial investigation activities. At the same time, nowadays, sustainable manufacturing design is one of the main responsibilities of the researchers looking at UN2030 agenda and the modern industrial paradigms. In this paper a new severe SPD process is proposed with the aim to steer manufacturing to fourth industrial revolution using some of Industry 4.0 pillars. In particular, additive manufacturing (AM) and numerical simulations were setup as controlling and monitoring techniques in manufacturing process of wires. Strengthening effect (yield and ultimate tensile strength, plasticity and hardness) and microstructural evolution (continuous dynamic recrystallization -CDRX-) due to severe plastic deformation were experimentally analysed and numerically investigated by an innovative finite element (FE) model able to validate the effectiveness of a properly modified process for ultra-fine aluminium alloy AA6101 wires production designed with the aim to avoid any post manufacturing costly thermal treatment. The study provides an accurate experimental study and numerical prediction of the thermo-mechanical and microstructural phenomena that occur during an advanced large plastic deformation process; it shows how the combination of smart manufacturing and simulations control represents the key to renew the traditional manufacturing methods in the perspective of the Industry 4.0, connecting and integrating the manufacturing process for the industrial evolution in production.

scholarly journals Finite element modelling of microstructural changes during equal channel angular drawing of pure aluminium

2021 ◽  
Author(s):  
Serafino Caruso ◽  
Stano Imbrogno
Keyword(s):  
Plastic Deformation ◽  
Grain Size ◽  
Finite Element ◽  
Size Variation ◽  
Fe Model ◽  
Pure Aluminium ◽  
Continuous Dynamic Recrystallization ◽  
Research Activities ◽  
Hardness Change ◽  
Continuous Dynamic

AbstractGrain refinement by severe plastic deformation (SPD) techniques, as a mechanism to control microstructure (recrystallization, grain size changes,…) and mechanical properties (yield strength, ultimate tensile strength, strain, hardness variation…) of pure aluminium conductor wires, is a topic of great interest for both academic and industrial research activities. This paper presents an innovative finite element (FE) model able to describe the microstructural evolution and the continuous dynamic recrystallization (CDRX) that occur during equal channel angular drawing (ECAD) of commercial 1370 pure aluminium (99.7% Al). A user subroutine has been developed based on the continuum mechanical model and the Hall-Petch (H-P) equations to predict grain size variation and hardness change. The model is validated by comparison with the experimental results and a predictive analysis is conducted varying the channel die angles. The study provides an accurate prediction of both the thermo-mechanical and the microstructural phenomena that occur during the process characterized by large plastic deformation.

Computation on continuous grain refinement in AA1050 aluminum during repetitive tube expansion and shrinking technique

2015 ◽  
Vol 232 (4) ◽  
pp. 307-318
Author(s):  
H Jafarzadeh ◽  
K Abrinia
Keyword(s):  
Finite Element Method ◽  
Plastic Deformation ◽  
Grain Size ◽  
Finite Element ◽  
Dislocation Density ◽  
Severe Plastic Deformation ◽  
Grain Refinement ◽  
Half Cycle ◽  
Tube Expansion ◽  
Element Method

The microstructure evolution during recently developed severe plastic deformation method named repetitive tube expansion and shrinking of commercially pure AA1050 aluminum tubes has been studied in this paper. The behavior of the material under repetitive tube expansion and shrinking including grain size and dislocation density was simulated using the finite element method. The continuous dynamic recrystallization of AA1050 during severe plastic deformation was considered as the main grain refinement mechanism in micromechanical constitutive model. Also, the flow stress of material in macroscopic scale is related to microstructure quantities. This is in contrast to the previous approaches in finite element method simulations of severe plastic deformation methods where the microstructure parameters such as grain size were not considered at all. The grain size and dislocation density data were obtained during the simulation of the first and second half-cycles of repetitive tube expansion and shrinking, and good agreement with experimental data was observed. The finite element method simulated grain refinement behavior is consistent with the experimentally obtained results, where the rapid decrease of the grain size occurred during the first half-cycle and slowed down from the second half-cycle onwards. Calculations indicated a uniform distribution of grain size and dislocation density along the tube length but a non-uniform distribution along the tube thickness. The distribution characteristics of grain size, dislocation density, hardness, and effective plastic strain were consistent with each other.

MULTI-SCALE FINITE ELEMENT SIMULATION OF SEVERE PLASTIC DEFORMATION

2009 ◽  
Vol 23 (06n07) ◽  
pp. 1621-1626
Author(s):  
HYOUNG SEOP KIM
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Severe Plastic Deformation ◽  
Constitutive Model ◽  
Dislocation Cell ◽  
Ultrafine Grain ◽  
Angular Pressing ◽  
Element Simulation ◽  
Ultrafine Grain Size ◽  
Ultrafine Grained

The technique of severe plastic deformation (SPD) enables one to produce metals and alloys with an ultrafine grain size of about 100 nm and less. As the mechanical properties of such ultrafine grained materials are governed by the plastic deformation during the SPD process, the understanding of the stress and strain development in a workpiece is very important for optimizing the SPD process design and for microstructural control. The objectives of this work is to present a constitutive model based on the dislocation density and dislocation cell evolution for large plastic strains as applied to equal channel angular pressing (ECAP). This paper briefly introduces the constitutive model and presents the results obtained with this model for ECAP by the finite element method.

Superplasticity of Aerospace 7075 (Al-Zn-Mg-Cu) Aluminium Alloy Obtained by Severe Plastic Deformation

2018 ◽  
Vol 385 ◽  
pp. 39-44 ◽  
Author(s):  
Fernando Carreño ◽  
Oscar A. Ruano
Keyword(s):  
Mechanical Properties ◽  
Plastic Deformation ◽  
Severe Plastic Deformation ◽  
Aluminium Alloy ◽  
Room Temperature ◽  
Grain Boundary Sliding ◽  
Strain Rates ◽  
Aerospace Applications ◽  
Boundary Sliding ◽  
Processing Stress

The 7075 (Al-Zn-Mg-Cu) aluminium alloy is the reference alloy for aerospace applications due to its specific mechanical properties at room temperature, showing excellent tensile strength and sufficient ductility. Formability at high temperature can be improved by obtaining superplasticity as a result of fine, equiaxed and highly misoriented grains prone to deform by grain boundary sliding (GBS). Different severe plastic deformation (SPD) processing routes such as ECAP, ARB, HPT and FSP have been considered and their effect on mechanical properties, especially at intermediate to high temperatures, are studied. Refined grains as fine as 100 nm and average misorientations as high as 39o allow attainment of high strain rate superplasticity (HSRSP) at lower than usual temperatures (250-300oC). It is shown that increasing misorientations are obtained with increasing applied strain, and increasing grain refinement is obtained with increasing processing stress. Thus, increasing superplastic strains at higher strain rates, lower stresses and lower temperatures are obtained with increasing processing strain and, specially, processing stress.

Superplasticity in a 5024 Aluminium Alloy Processed by Severe Plastic Deformation

2012 ◽  
Vol 735 ◽  
pp. 353-358 ◽  
Author(s):  
Anna Mogucheva ◽  
Diana Tagirova ◽  
Rustam Kaibyshev
Keyword(s):  
Plastic Deformation ◽  
Severe Plastic Deformation ◽  
Strain Rate ◽  
Aluminium Alloy ◽  
Initial Strain Rate ◽  
Strain Rates ◽  
Superplastic Behaviour ◽  
Angular Pressing ◽  
Elongation To Failure ◽  
Zr Alloy

The superplastic behaviour of an Al-4.6%Mg-0.35%Mn-0.2%Sc-0.09%Zr alloy was studied in the temperature range 250-500°C at strain rates ranging from 10-4 to 10-1 s-1. The AA5024 was subjected to equal channel angular pressing (ECAP) at 300°C up to ~12. The highest elongation-to-failure of ∼3300% was attained at a temperature of 450°C and an initial strain rate of 5.6×10-1 s-1. Regularities of superplastic behaviour of the 5024 aluminium alloy are discussed.

Study of a modified ECAP die for producing nanostructured Al6060 alloy using 3D finite element simulation

2016 ◽  
Vol 1818 ◽  
Author(s):  
M. A. González-Lozano ◽  
P. Ponce-Peña ◽  
M.A. Escobedo-Bretado ◽  
R.H. Lara-Castro ◽  
B. X. Ochoa-Salazar
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Severe Plastic Deformation ◽  
Tensile Stress ◽  
Deformation Zone ◽  
Plastic Deformation Zone ◽  
Element Analysis ◽  
Ecap Processing ◽  
Angular Pressing ◽  
Element Simulation

ABSTRACTUsing Finite Element Method (FEM) simulations is possible to study the homogeneity of deformation in the Equal Channel Angular Pressing (ECAP) process. In this work an investigation about the influence of a modified die on strain distribution in an ecaped Al6060 alloy was carried out. Due to that, tensile stress occurs in the vicinity of upper surface of the specimen in the severe plastic deformation zone, which increases the cracking and fracture tendency of the specimen and impedes further ECAP processing, the conventional ECAP die was modified to eliminate the tensile stress and enhance the compressive stress in the severe plastic deformation zone and reducing the cracking and fracture tendency of the specimen. Finite element analysis demonstrated that the stress state changes from tensile to strongly compressive when using the modified die. The aim of this study is to evaluate the advantages/disadvantages of the modified ECAP die and processing conditions.

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