Guanyu Deng

Numerical Simulation of Temperature Field and Thermal Stress Field of Work Roll During Hot Strip Rolling

Based on the thermal conduction equations, the threedimensional (3D) temperature field of a work roll was investigated using finite element method (FEM). The variations in the surface temperature of the work roll during hot strip rolling were described, and the thermal stress field of the work roll was also analyzed. The results showed that the highest roll surface temperature is 593 °C, and the difference between the minimum and maximum values of thermal stress of the work roll surface is 145. 7 MPa. Furthermore, the results of this analysis indicate that temperature and thermal stress are useful parameters for the investigation of roll thermal fatigue and also for improving the quality of strip during rolling.

Tribological Behavior of Aqueous Copolymer Lubricant in Mixed Lubrication Regime.

Although a number of experiments have been attempted to investigate the lubrication of aqueous copolymer lubricant, which is applied widely in metalworking operations, a comprehensive theoretical investigation at atomistic level is still lacking. This study addresses the influence of loading pressure and copolymer concentration on the structural properties and tribological performance of aqueous copolymer solution of poly(propylene oxide)-poly(ethylene oxide)-poly(propylene oxide) (PPO-PEO-PPO) at mixed lubrication using a molecular dynamic (MD) simulation. An effective interfacial potential, which has been derived from density functional theory (DFT) calculations, was employed for the interactions between the fluids molecules and iron surface. The simulation results have indicated that the triblock copolymer is physisorption on iron surface. Under confinement by iron surfaces, the copolymer molecules form lamellar structure in aqueous solution and behave differently from its bulk state. The lubrication performance of aqueous copolymer lubricant increases with concentration, but the friction reduction is insignificant at high loading pressure. Additionally, the plastic deformation of asperity is dependent on both copolymer concentration and loading pressure, and the wear behavior shows a linear dependence of friction force on the number of transferred atoms between contacting asperities.

A study of plastic deformation behavior during high pressure torsion process by crystal plasticity finite element simulation

High pressure torsion (HPT) is an efficient technique of producing ultrafine grained materials with exceptional small grain size. In this study, a crystal plasticity finite element method (CPFEM) model has been developed to investigate the plastic deformation behavior of pure aluminum single crystal during the HPT process. The simulation results show that, the distribution and evolution of the macroscopic plastic strain and the accumulative shear strain are similar. The value increases with the increase of the distance from the center as well as the number of revolution. The simulation is capable of reflecting the anisotropic characteristics of HPT deformation, a non-homogenous deformation along the circumference of the sample could be observed. At the early stage of HPT deformation, the critical resolved shear stress (CRSS) along the radial direction presents a rapid increase, followed by a moderate increase and then reaches the near-saturate state. As the HPT deformation proceeds, there is a relatively weak increase in the quasi-saturate value and the near-steady region expands gradually towards the sample center. The orientation changes during the HPT process with increasing applied strain predicted by the developed CPFEM model are also presented.

Tension/compression asymmetry of grain boundaries with non-planar structure

Molecular dynamics simulations were carried out to investigate the mechanical property and the deformation mechanisms of Cu bicrystal with non-planar structured grain boundaries (GBs) under uniaxial tension and compression. The simulation results showed that the non-planar GBs could change their equilibrium configurations under the applied stress, and the deformation mechanisms varied when altering the misorientation angle. The stacking fault energy curve was affected by the stress perpendicular to the slip plane and therefore has an influence on the dislocation nucleation mechanisms. Previous studies have revealed a ubiquitous tension/compression (T/C) strength asymmetry of many ultra-fine or nanocrystalline materials, and a higher compressive strength was usually reported. However, in the present study, the bicrystal samples with non-planar structured GBs show a higher tensile strength than the compressive one. The unusual T/C asymmetry property has an implication that the GBs with non-planar structure can play a significant role in affecting the mechanical properties of nanostructured materials.

Numerical evaluation of a high speed steel work roll during hot strip rolling process

Hot strip rolling process is one of the most promising industrial processes to fabricate finished or semi-finished bulk products. Numerical analysis on the temperature and thermal stress distributions in a high speed steel work roll during hot rolling has been conducted based on a transient thermo-mechanical model. Influence of initial work roll body temperature on temperature and thermal stress has been discussed in detail by assuming different rolling stages. Compared to the work roll surface, stress is much smaller at depth of 2.1 mm and 5.0 mm, respectively. Results showed similar maximum circumferential thermal stress at both depths of 2.1 mm and 5.0 mm when the roll has initial temperature of 25 °C and 100 °C, but they are about 3 times and 8 times larger than at depth of 2.1 mm and 5.0 mm, respectively, when the initial temperature is 200 °C.

Optimization and application of process parameters in an AZ61 alloy twin-roll strip casting

Twin-roll strip casting is a concerned technology for economically producing magnesium alloys sheets. In this paper, numerical simulation of the twin-roll strip casting of an AZ61 magnesium alloy was carried out and the optimal process parameters were obtained. Then, under the conditions obtained through simulation, AZ61 strips of good surface quality were successfully manufactured. The microstructure of the alloy by twin-rolled strip casting is obvious refined compared with that by conventional casting.

A Study on the Aluminum Alloy AA1050 Severely Deformed by Non-Equal Channel Angular Pressing

In order to improve the efficiency of grain refinement, a study on the modified process (called Non-equal channel angular pressing) from the conventional equal channel angular pressing has been conducted. The deformation behavior of aluminum alloy AA1050 deformed by the Non-equal channel angular pressing which has a smaller width in the exit channel than the entry channel was examined based on the finite element simulations. The results revealed that a smaller ratio of dE and dI (dE/dI) leads to a larger equivalent plastic strain. It is not only beneficial to enhance the plastic deformation but also very helpful to get rid of the development of dead zone in the outer corner of die by decreasing the exit channel width by comparing with the conventional process.

Hertz Contact at the Nanoscale with a 3D Multiscale Model

This paper presents a three-dimensional multiscale computational model, which is proposed to combine the simplicity of FEM model and the atomistic interactions between two solids. A significant advantage of the model is that atoms are populated in the contact regions, which saves significant computation time compared to fully MD simulations. The model is used in the case of asperity contact. The normal displacement, contact radius and pressure distribution are compared with those from Hertz’s solution and atomistic simulations in the literature. Some important features of nanoscale contacts obtained by MD simulations can be caught by the model with acceptable accuracy and low computational cost.

Finite-Temperature Multiscale Simulations for 3D Nanoscale Contacts

A finite-temperature analysis of a multiscale model, which couples finite element and molecular dynamics, is presented in this paper. The model is evaluated by the patch test and demonstrates its capacity. Then, the multiscale scheme is used to study 3D nanoscale contacts. The linear relationship between the contact area ratio and load is observed at small loads, but the temperature effect is small. However, the change in the root mean square (RMS) of heights depends on the temperature at high loads.

Modelling of Texture Evolution in High Pressure Torsion by Crystal Plasticity Finite Element Method

In this study, texture evolution during high pressure torsion (HPT) of aluminum single crystal is predicted by the crystal plasticity finite element method (CPFEM) model integrating the crystal plasticity constitutive theory with Bassani & Wu hardening model. It has been found by the simulation that, during the HPT process, the lattice rotates mainly around the radial direction of the sample. With increasing HPT deformation, the initial cube orientation rotates progressively to the rotated cube orientation, and then to the C component of ideal torsion texture which could be remained over a wide strain range. Further HPT deformation leads to the orientation towards to the ideal texture component.