Inverse Approach of Parameter Optimization for Nonlinear Meta-Model Using Finite Element Simulation

Accurate and efficient estimation and prediction of the nonlinear behavior of materials during plastic working is a major issue in academic and industrial settings. Studies on property meta-models are being conducted to estimate and predict plastic working results. However, accurately representing strong nonlinear properties using power-law and exponential models, which are typical meta-models, is difficult. The combination meta-model can be used to solve this problem, but the possible number of parameters increases. This causes a cost problem when using FE simulation. In this study, the accuracy of the nonlinear properties of materials and the number of iterations were compared for three typical meta-models and the proposed advanced meta-models considering stress–strain properties. A material property test was conducted using ASTM E8/E8M, and the meta-model was initialized using ASTM E646 and MATLAB Curve Fitting Toolbox. A finite element (FE) simulation was conducted for the meta-models, and the test and simulation results were compared in terms of the engineering stress–strain curve and the root-mean-square error (RMSE). In addition, an inverse method was applied for the FE simulation to estimate the true stress–strain properties, and the results were analyzed in terms of the RMSE and the number of iterations and simulations. Finally, the need for an advanced meta-model that exhibits strong nonlinearity was suggested.

Modeling of Microstructure Evolution during Deformation Processes by Cellular Automata—Boundary Conditions and Space Reorganization Aspects

Cellular automata (CA) are efficient and effective numerical tools for modeling various phenomena and processes, e.g., microstructure evolution in plastic working processes. In many cases, the analysis of phenomena can be carried out only in a limited space and on representative volume. This limitation determines the geometry of CA space hence boundary conditions are very important issues in modeling. The paper discusses different boundary conditions that can be applied to modeling. Taking into account the transformation of the modeling space, the model should allow the selection of boundary conditions. The modeling of certain phenomena and processes is directly related to changes in the geometry of a representative volume and therefore may require changes or reorganization of the modeled CA space. Four reorganization options are presented: halving, cutting and bonding, doubling, and straightening. A choice of boundary conditions may depend on particular space reorganization as used for the modeling of microstructure evolution. A set of decision rules for selecting space reorganization options taking into account the changes of CA shape and sizes is also presented. The modeling of flat and shape rolling processes utilizing some of the described techniques is shown.

Forming Processes of Modern Metallic Materials

The plastic working of metallic materials is one of the most efficient and important manufacturing technologies used in industry today [...]

The Experimental and Numerical Research for Plastic Working of Nickel Matrix Composite Coatings

In the machine, metallurgical, and shipbuilding industries, steel products with alloy and composite coatings based on nickel may be used. It is expedient to improve the physicochemical properties of the surface layer of products as they have a significant roughness value after thermal spraying. It is therefore important to finish the layers applied by flame spraying, where machining is used for this purpose. However, it causes a loss of coating material, which is quite expensive. Therefore, in order to reduce costs and improve the quality of the surface layer, the finishing treatment of nickel-based coatings by means of plastic working is used. Two types of plastic working were proposed: rolling and burnishing. Numerical and experimental tests of the plastic processing of alloy coatings were carried out. The roughness of the coatings after rolling decreased to 1/25 and 30% strengthening of the alloy coating matrix was determined. After burnishing, roughness was reduced to 1/12 and the alloy coatings were strengthened by 25%. Plastic working by rolling and burnishing has a beneficial effect on the surface quality of the workpiece, not only by significantly improving the roughness, but also by increasing the strength properties of the surface layers.

EFFECT OF THE PLASTIC STRAIN AND DRAWING QUALITY ON THE FRICTIONAL RESISTANCE OF STEEL SHEETS

The aim of the research presented in this article is to investigate the frictional resistance of steel sheets with different drawing quality. Friction tests have been carried out using the bending under tension (BUT) test which simulates the contact conditions at the rounded edges of the punch and die in sheet metal forming operations. The effect of sheet deformation and temper state on the value of the coefficient of friction has been studied. It was found that increasing the value of elongation of the sheet is associated with an increase in the value of the COF for both friction conditions analysed. The intensity of work hardening, by changing the mechanical properties of the sheet, is a factor that changes contact conditions. The lubricant which is typically used in plastic working provided a reduction of frictional resistance by approximately 3.6-14%, depending on the degree of sheet deformation.

Evaluation of Structure and Corrosion Behavior of FeAl Alloy after Crystallization, Hot Extrusion and Hot Rolling

The paper presents the results of tests on the corrosion resistance of Fe40Al5Cr0.2TiB alloy after casting, plastic working using extrusion and rolling methods. Examination of the microstructure of the Fe40Al5Cr0.2TiB alloy after casting and after plastic working was performed on an Olympus GX51 light microscope. The stereological relationships of the alloy microstructure in the state after crystallization and after plastic working were determined. The quantitative analysis of the structure was conducted after testing with the EBSD INCA HKL detector and the Nordlys II analysis system (Channel 5), which was equipped with the Hitachi S-3400N microscope. Structure tests and corrosion tests were performed on tests cut perpendicular to the ingot axis, extrusion direction, and rolling direction. As a result of the tests, it was found that the crystallized alloy has better corrosion resistance than plastically processed material. Plastic working increases the intensity of the electrochemical corrosion of the examined alloy. It was found that as-cast alloy is the most resistant to corrosion in a 5% NaCl compared with the alloys after hot extrusion and after hot rolling. The parameters in this study show the smallest value of the corrosion current density and corrosion rate as well as the more positive value of corrosion potential.

Peculiarities of Alloying Effect on the Eutectic Cementite Behavior Under Hot Rolling

Currently, cast iron remains one of the major modern casting materials in metallurgy and machine-building industry and is sure to take the lead in the future. Chilled cast iron has high hardness and wear resistance due to a large number of carbide phases in its structure. However, low ductility and impact hardness essentially limit its applicability in terms of processing. Hot plastic working, under which the eutectic net crushing is observed, appears to be one of the most effective means of the eutectic alloy products shape and microstructure transformation. Chilled cast iron properties fundamentally improve after hot plastic working: ductility, strength and impact hardness increase by 2-3 times on retention of the high hardness factor. Chilled cast iron ductility increase can be attained when using phase transformations in eutectic cementite under lean alloying with carbide forming elements. The purpose of the paper is to study alloying effect on the chilled cast iron ductility as well as eutectic cementite behavior under hot rolling. In the paper hardening and softening of the structural components in chilled cast iron under hot working have been studied. The deformation texture forming in eutectic cementite under hot rolling has been revealed, which is connected with the dynamic softening and depends on the degree and the nature of its alloying. The mechanism and regularities of the phase transformation effect in cementite on its behavior under plastic deformation and on the alloys ductility in general have been studied. In cementite chromium alloying initiates processes, that can be characterized as the pre-precipitation stage of the new phases, and this way it contributes to the cast iron ductility reduction and embrittles cementite. Carbide transformation, that occurs in eutectic cementite under alloying with vanadium, stimulates softening of the alloy and increases its ductility level. Moreover, the multiple glide planes {130},{011},{112} in cementite have been determined. It has been found out, that in supersaturated cementite vanadium carbides precipitation stimulates the extra glide plane {111} occurrence under hot rolling. The essence of the carbide transformation phenomenon is that under hot working there occurs the lubricating effect at the transition of the metastable iron carbide condition, which is strengthened with vanadium supersaturation and mechanical hardening, to a more stable condition due to precipitation of the proeutectoid constituents on the one hand, and because of the dynamic softening processes on the other hand. At that, the autocatalyticity effect is observed: there is precipitation of carbides with hardening and softening, similar to the processes that arise as a result of the superplastic effect induced by phase transformations.