Physical and numerical modelling of forging accounting for exploitation properties of products

Physical and numerical modelling of forging accounting for exploitation properties of products

Lukasz Madej1, Danuta Szeliga1, Roman Kuziak2, Maciej Pietrzyk1

1Department of Applied Computer Science and Modelling Akademia Gorniczo Hutnicza, Krakow, Poland.
2Institute for Ferrous Metallurgy, Gliwice, Poland.

DOI:

https://doi.org/10.7494/cmms.2007.4.0177

Abstract:

Idea of modelling of the life cycle of materials is presented and benefits of this approach are stated in the paper. Simulation of the entire life cycle of materials creates a possibility that properties of products can be controlled at the stage of technology design for materials processing and manufacturing. All steps of this methodology are discussed using production of connecting parts as an example. Investigation of the role of forging in the production chain is the particular objective of the project but other processes are considered, as well. Description of the experimental stages related to material structure development and investigation of material properties under loading conditions are supported by the numerical investigations. Results obtained from FE (Finite Element) simulations with the conventional rheological model and from the multi scale CAFE (Cellular Automata in Finite Element) model of the connecting parts forging processes are presented and discussed in the paper. Particular attention is put on strain localization development during cold forging and its influence on properties of products.

Cite as:

Madej, L., Szeliga, D., Kuziak, R. & Pietrzyk, M., (2007). Physical and numerical modelling of forging accounting for exploitation properties of products. Computer Methods in Materials Science, 7(4), 397 – 405. https://doi.org/10.7494/cmms.2007.4.0177

Article (PDF):

Keywords:

Life cycle of material, Multi scale modelling, Forging

References:

Anand, L., Spitzig, A., 1980, Initiation of localized shear bands in plane strain, J. Mech. Phys. Solids, 28, 113-128.

Beynon, J.H., Das, S., Howard, I.C., Palmier, E.J., Shterenlikht, A., 2000, The combination of cellular automata and finite elements for the study of fracture; the CAFE model of fracture, Proc. Conf., ECF14, eds, Neimitz, A., Rokach, I.V., Kocanda, D., Golos, K., Krakow, 241-248.

Cizek, P., 2002, Characteristics of shear bands in an austenitic stainless steel during hot deformation, Mat. Sci. Eng., A324, 214-218.

Gavrus, A., Massoni, E., Chenot, J.L., 1996, An inverse analysis using a finite element model for identification of rheological parameters, J. Mat. Proc. Techn., 60, 447-454.

Harren, S.V., Deve, H.E., Asaro, R.J., 1988, Shear band formation in plane strain compression, Acta Metall., 36, 2435-2480.

Korbel, A., 1998, Structural and mechanical aspects of homogeneous and non-homogeneous deformation in solids, Courses and Lectures – No. 386, Springer, 21-98.

Madej, L., Hodgson, P.D., Pietrzyk, M., 2006, Multi scale analysis of material behavior during deformation processes, in: Foundation of Materials Design, eds, Kurzydlowski, J.K., Major, B., Zieba, P., Research Signpost, Kerala, 17-47.

Madej, L., Hodgson, P.D., Pietrzyk, M., 2007, Multi-scale rheological model for discontinuous phenomena in materials under deformation conditions, Computational Materials Science, 38, 2007, 685-691.

Madej, L., Hodgson, P.D., Zmudzki, A., Pietrzyk, M., 2006, Possibilities of application of the multi scale strain localization CAFE model, Proc. 4th ECCM, Lisboa, (CD ROM).

Makarov, P.V., 2000, Localized deformation and fracture of polycrystals at mesolevel, Theor. Appl. Fract. Mech., 33, 23-30.

Olivier, J., 1995, Continuum modelling of strong discontinuities in solid mechanics, Proc. Conf. COMPLAS’95, eds, Owen, D.R.J., Onate, E., Barcelona, 455-479.

Park, K.S., Park, K-T, Lee, D.L., Lee, C.S., 2005, Comparison of cold formability of cold drawn non-heat-treated steels having similar strength, ISIJ Int., 45, 1352-1357.

Pecherski, R.B., 1998, Macroscopic effect of micro-shear banding in plasticity of metals, Acta. Mech., 131, 203-224.

Pickering, B.F., 1996, High-Strength, low–alloy steel – a decade of progress, in Proc. Symp. Microalloying, ed., Korchynsky, M., Union Carbide Computation, New York, 9-31.

Sematin, S.L., Laohoti, G.D., 1982, The occurrence of shear bands in the isothermal hot forging, Metall. Trans. A, 13A, 275-287.

Shterenlikht, A., 2003, 3D CAFE Modeling of transitional ductile – brittle fracture in steels, PhD Thesis, University of Sheffield, Sheffield.

Szeliga, D., Gawąd, J., Pietrzyk, M., 2006, Inverse Analysis for Identification of Rheological and Friction Models in Metal Forming, Comp. Meth. Appl. Mech. Engrg., 195, 6778-6798.

Zajac, S., 2004, Intense Precipitation Strengthening of Bainitic Flat and Long Products – Mechanisms, Means and Process Routes, RFS-project PREST, Stockholm, 2004-2007.