Alireza Asgari

Temperature variations at nano-scale level in phase transformed nanocrystalline NiTi shape memory alloys adjacent to graphene layers

The detection and control of the temperature variation at the nano-scale level of thermo-mechanical materials during a compression process have been challenging issues. In this paper, an empirical method is proposed to predict the temperature at the nano-scale level during the solid-state phase transition phenomenon in NiTi shape memory alloys. Isothermal data was used as a reference to determine the temperature change at different loading rates. The temperature of the phase transformed zone underneath the tip increased by ∼3 to 40 °C as the loading rate increased. The temperature approached a constant with further increase in indentation depth. A few layers of graphene were used to enhance the cooling process at different loading rates. Due to the presence of graphene layers the temperature beneath the tip decreased by a further ∼3 to 10 °C depending on the loading rate. Compared with highly polished NiTi, deeper indentation depths were also observed during the solid-state phase transition, especially at the rate dependent zones. Larger superelastic deformations confirmed that the latent heat transfer through the deposited graphene layers allowed a larger phase transition volume and, therefore, more stress relaxation and penetration depth.

Design of experiments and springback prediction for AHSS automotive components with complex geometry

With the drive towards implementing Advanced High Strength Steels (AHSS) in the automotive industry; stamping engineers need to quickly answer questions about forming these strong materials into elaborate shapes. Commercially available codes have been successfully used to accurately predict formability, thickness and strains in complex parts. However, springback and twisting are still challenging subjects in numerical simulations of AHSS components. Design of Experiments (DOE) has been used in this paper to study the sensitivity of the implicit and explicit numerical results with respect to certain arrays ofuser input parameters in the forming ofan AHSS component. Numerical results were compared to experimental measurements of the parts stamped in an industrial production line. The forming predictions of the implicit and explicit codes were in good agreement with the experimental measurements for the conventional steel grade, while lower accuracies were observed for the springback predictions. The forming predictions of the complex component with an AHSS material were also in good correlation with the respective experimental measurements. However, much lower accuracies were observed in its springback predictions. The number of integration points through the thickness and tool offset were found to be of significant importance, while coefficient of friction and Youngs modulus (modeling input parameters) have no significant effect on the accuracy of the predictions for the complex geometry.

Sheet forming simulation for AHSS components in the automotive industry

The trend in the automotive industry towards new advanced high strength steels (AHSS), combined with the ongoing reduction in program lead times have increased the need to get tool designs right, first time. Despite the fact that the technology used by sheet metal stamping companies to design and manufacture tooling is advancing steadily, finding optimal process parameters and tool geometries remains a challenge. Consequently, there has been a transition from designs based largely on trial and error techniques and the experience of the stamping engineer, to the increased use of virtual manufacturing and finite element (FE) simulation predictions as an indispensable tool in the design process. This work investigates the accuracy of FE techniques in predicting the forming behavior of AHSS grades, such as TRIP and dual phase, as compared to more commonly used conventional steel grades. Three different methods of simulation, one-step, implicit and explicit techniques, were used to model the forming process for an automotive part. Results were correlated with experimental strain and thickness measurements of manufactured components from the production line.

A systems approach to shape and topology optimisation of mechanical structures

Optimisation techniques have become more and more important as the possibility of simulating complex mechanical structures has become a reality. A common tool in the layout design of structural parts is the topology optimisation method, which finds an optimum material distribution within a given geometrical design space to best meet loading conditions and constraints. Another important method is shape optimisation, which optimises weight given parametric geometric constraints. In the case of complex shaped parts or elaborate assemblies, for example automobile body structures, shape optimisation is still hard to do; mainly due to the difficulty in translating shape design parameters into meaningful analysis models. Tools like the parametric geometry package SFE CONCEPT are designed to mitigate these issues. Nevertheless, shape methods usually cannot suggest new load path configurations, while topology methods are often confined to single parts. To overcome these limitations the authors have developed a method that combines both approaches into an Integral Shape/Topology Method (IST) that is capable of finding new optimal solutions. This is achieved by an automated optimisation loop and can be applied for both thin walled structures as well as solid 3D geometries. When optimising structures by applying IST, global optimum solutions can be determined that may not be obtained with isolated shape- or topology-optimisation methods.

Simulation of Three-Point Bending Test of Titanium Foam for Biomedical Applications

Using Titanium (Ti) foam as an implant material is a new approach for biomedical applications and it is important to understand the mechanical behaviors of this new foam material. In the present study, the bending of the Ti foam has been simulated and compared against recently published data [1]. FE Analysis has been performed by Abaqus software. Stiffness and Yield strength of foams between 50% (cortical bone) to 80% (cancellous bone) porosity range were considered. This study showed that crushable foam material model in Abaqus, which has developed primarily for Aluminum (Al) foam alloys, is also valid for Ti Foam before any crack or damage occurs in the sample.

MICROSTRUCTURE MODELING AND PREDICTION OF THE MECHANICAL PROPERTIES OF ADVANCED HIGH STRENGTH STEELS

Dual phase (DP) steels were modeled using 2D and 3D representative volume elements (RVE). Both the 2D and 3D models were generated using the Monte-Carlo-Potts method to represent the realistic microstructural details. In the 2D model, a balance between computational efficiency and required accuracy in truly representing heterogeneous microstructure was achieved. In the 3D model, a stochastic template was used to generate a model with high spatial fidelity. The 2D model proved to be efficient for characterization of the mechanical properties of a DP steel where the effect of phase distribution, morphology and strain partitioning was studied. In contrast, the current 3D modeling technique was inefficient and impractical due to significant time cost. It is shown that the newly proposed 2D model generation technique is versatile and sufficiently accurate to capture mechanical properties of steels with heterogeneous microstructure.

Investigation on forming limit properties of dual phase steel

The accurate representation of the forming limit properties in the material model is very important for predicting the onset of failure. In this study, the FLCs for two dual phase steels DP780 and DP600 were experimentally obtained. The FLSCs were derived numerically by setting up stretching models in ABAQUS in which experimental FLD data were employed as failure criteria. The results of FLSCs showed in good agreement with that transformed from theoretical calculation. A new type of forming limit diagram based on Polar representation of EPS (Effective Plastic Strain) which proposed by Stoughton and Yoon was conducted to analyse the difference of result caused by FLD and FLSD criteria. The forming processes of a special cup-type part drawing were modelled and simulated by utilizing FLD and FLSD as failure criteria, respectively. According to analysis, the Polar EPS diagram can intuitively describe formability problems in forming processes. To avoid the occurrence of failure, it was found that if strain pat...

Fracture of DP590 steel : a multi-scale modeling approach

Various analytical rules of mixture are commonly used to take into account heterogeneous features of a material and to derive global properties. But, with such models, one may not be able to fulfil the requirements for separating appropriately the different lengthscales. This might be the case for some issues such as strain localisation, surface effect, or topological distributions. At an intermediate lengthscale, which we refer to as the mesoscopic scale, one can still apply continuum mechanics. So why not perform calculations using the finite element method on volumes of material to obtain the response of Representative Elementary Volumes (R.E.V.). The construction of digital microstructures for such calculations is performed in two steps. First, a series of R.E.V.s with statistics of features of real materials should be defined. Then, finite element meshes should be produced for these R.E.V.s and updated when calculations involve large strains. Powerful automatic three-dimensional mesh generators and remeshing techniques prove necessary for this latter task. This strategy is applied to create digital R.E.V.s which match statistical features of forgings. Measurements provide micromechanical parameters of each subvolume. As an example of calculations, numerical simulations provide the anisotropic fatigue properties of forgings.