Luciano Pessanha Moreira

Sensitivity analysis of the ECAE process via 2 k experiments design

In this work the theoretical solutions based upon the upper-bound theorem recently proposed by Perez and Luri [Mech. Mater. 40 (2008) 617] for the equal channel angular extrusion process (ECAE) are analyzed by performing a 25 central composite factorial analysis. The uniaxial mechanical properties of commercial pure aluminium are considered by assuming isotropic nonlinear work-hardening combined to von Mises and Drucker isotropic yield criteria to predict the ECAE load and the effective plastic strain. From the proposed 25 factorial analysis, the main parameters affecting the ECAE pressure may be ranked as: (1) Friction factor, (2) die channels intersection angle, (3) outer and (4) inner die corners fillet radii and lastly, (5) plunger velocity. Alternatively, the effective plastic strain is mainly controlled by the die channels intersection angle and, in a less extent, by the outer and inner die corners fillet radii.

Densification Behaviour Modelling for Metallic Powders

Powder forming involves fabrication of a preform by conventional press-and-sinter processing, followed by various forming processes, citing as examples, rolling, compaction, forging, extrusion, among others, of the porous preform into a final shape through substantial densification. This work makes a finite element analysis for porous metals. The finite element model was applied to simulating the case of compaction of nanocristalline copper under uniaxial compression conditions in order investigate the densification behavior. The model was simulated using explicit integration method as applied to the evolution variation of the relative density and the dislocation density of the compact. Finite element analysis program used was Abaqus. Finite element calculations were compared with literature data. The agreements between finite element model and literature results for densification of nanocristalline copper were good.

Experimental analysis and theoretical predictions of the limit strains of a hot-dip galvanized interstitial-free steel sheet

In this work, the formability of a hot-dip galvanized interstitial-free (IF) steel sheet was evaluated by means of uniaxial tensile and Forming Limit Curve (FLC) tests. The FLC was defined using the flat-bottomed Marciniaks punch technique, where the strain analysis was made using a digital image correlation software. A plastic localization model was also proposed wherein the governing equations are solved with the help of the Newtons method. The investigated hot-dip galvanized IF steel sheet presented a very good formability level in the deep-drawing range consistent with the measured Lankford values. The predicted limit strains were found to be in good agreement with the experimental data of the hot-dip galvanized IF steel sheet owing to the definition of the localization model geometrical imperfection as a function of the experimental surface roughness evolution and, in particular, to the yield surface flattening near to the plane-strain stress state authorized by the adopted yield criterion.

Modeling, simulation and identification for control of tandem cold metal rolling

This paper describes a modeling procedure for tandem cold metal rolling, including the linearization step and system identification for control. The tandem cold rolling process is described by a mathematical model based on algebraic equations developed for control purposes and empirical relations. A state-space model is derived and detailed analyses in open loop are presented, concerning the sensitivity with regard to the variations in process parameters and results for the application of a new subspace identification method are compared with classical methodologies. Therefore, this work intents to be a contribution for developments in new control strategies for tandem cold rolling process that offer the potential to reduce the design efforts, the commissioning time and maintenance in rolling mills. The preliminary results obtained with this model have shown reasonable agreement with operational data presented at literature for industrial cold rolling process.

Finite element analysis of the tube flow forming process

In this work, a numerical study is presented with to analyse the flow forming process as a function of the initial condition of the preform material, namely, in the as-received state and after quenching and tempering heat treatments. An industrial tube flow forming process is analysed with 2D plane-strain and 3D Finite Element (FE) models. The predictions indicate that the as-received condition gives slightly lower drawing forces in comparison to the quenching and tempering condition. Finally, the results determined with the 3D FE modelling show that the drawing forces strongly depend upon the element formulation adopted to describe the preform blank.

Strain-Induced Martensite Formation of AISI 304L Steel Sheet: Experiments and Modeling

Metastable austenitic stainless steels are prone to strain-induced martensite transformation (SIMT) during deformation at room temperature, as in the case of sheet metal forming processes. The SIMT is influenced by the chemical composition, grain size, temperature, deformation mode or stress state and strain-rate. In this work, interrupted and continuous uniaxial tensile tests were performed in AISI 304L sheet to evaluate the SIMT as a function of strain and strain-rate effects. The SIMT was evaluated by feritscope and temperature in-situ measurements and both XRD and optical microscopy techniques. The SIMT kinetics was also investigated by means of thermo-mechanical finite element simulations using a phenomenological model. In the small strain range, the yield stress increases with the strain-rate whereas in the large strain domain a cross-effect in the stress-strain curve is observed given that the SIMT is inhibited due to the specimen heat generation. A very good correlation between XRD and feritscope measurements was found from the interrupted uniaxial tensile testing. The finite element numerical simulations allowed to identify the parameters of a phenomenological model which describes the SIMT kinetics of AISI 304L steel sheet as a function of plastic-strain, strain-rate and temperature effects.

Elasto-Plastic Modeling of the Limit Strains in Metallic Sheets

In this work, the model of Marciniak and Kuczynski, hereafter referred to as the M-K model, was extended to account for the elastic strains to forecast the Forming Limit Curve (FLC) of metallic sheets. The return mapping algorithm is adopted where an elastic predictor step is performed with the generalized Hooke’s law and the plastic correction step is performed assuming the isotropic work-hardening together with the associated flow rule. The current M-K model predicted quite well both experimental and rigid-plastic results obtained for an IF steel sheet. Also, the principal stresses predicted by the elasto-plastic M-K model provided a good agreement with the experimental Forming Limit Stress Diagram (FLSD) of a Bake-Hardening steel sheet. Therefore, the elastic strains should be taken into account in the modeling of limit strains in metallic sheets, especially in the case of advanced high strength steels for which the Young modulus decreases with the plastic strain.

Experimental Analysis of Forming Limits and Thickness Strains of DP600-800 Steels

In this work, the plastic behavior of cold-rolled zinc coated dual-phase steel sheets DP600 and DP800 grades is firstly investigated by means of uniaxial tensile and Forming Limit Curve (FLC) testing. The uniaxial tensile tests were carried out at 0o, 45o and 90o angular orientations with respect to the rolling direction to evaluate the mechanical properties and the plastic anisotropy Lankford r-values. The forming limit strains are defined according to Nakajima’s procedure. Thickness measurements of tested Nakajima’s samples cut perpendicular to the fracture allowed to identify a rapid decrease of the strain, which governs the plastic instability that preceded the fracture in the drawing region of the FLC. Optical metallographic and scanning electron microscopy techniques helped to characterize and distinguish the orientation of rotated grains and flat fractured surface (ductile shear failure in blank specimens close to plane-strain tension) from no grain rotations and rough fractured surface (ductile tensile fracture in blank geometries in the biaxial stretching domain).

Modeling the Welding Process of the Low Alloy Ferritic Steels T/P23 and T/P24

In this paper a model based on transport equations is proposed to study the weldability of low alloy ferritic steels T/P23 and T/P24. The model was numerically implemented by using the finite volume method (FVM) in an open source computational code to simulate the influence of the heat input, base metal thickness and preheating temperature on the thermal evolution and the cooling rate during the welding process. Meanwhile, it was possible to evaluate qualitatively the microstructure at the heat affected zone (HAZ) of these steels when a single weld bead was deposited on their surface and calculate the maximum hardness reached at this region. A double-ellipsoid heat source model for power density distribution was used in order to obtain a good estimate of the cooling rate and evolution of the fusion zone (FZ). The results are discussed and good agreement between experimental and simulated results was obtained for temperature distribution

Micromechanical Modeling of DP600 and DP800 Steels Plastic Behavior Based on the Mori-Tanaka Homogenization Method

The properties of the dual-phase steels are attributed to the chemical composition, type, size, amount, and spatial distribution of different phases that can be obtained during thermomechanical treatments. In this way, modeling of the mechanical behavior of the dual-phase steel constituents, namely, ferrite and martensite, is crucial to the numerical simulation of sheet metal forming processes mainly to forecast the residual stresses per phase. In this work, the microstructure of as-received DP600 and DP800 cold rolled steel sheets with 1.2 mm nominal thickness were firstly characterized by means of scanning electron microscopy technique. The grain sizes and volume fractions of ferrite and martensite phases were obtained by means of digital image analysis. The Mori-Tanaka homogenization scheme was implemented in the finite element code ABAQUS assuming linear isotropic elasticity and isotropic work-hardening behavior for both ferrite (matrix) and martensite (inclusion) phases. The numerical predictions obtained with the Mori-Tanaka homogenization scheme for the macroscopic uniaxial tensile behavior are in good agreement with the experimental curves of both dual-phase steels.