Mads Rostgaard Sonne

Numerical Modeling of AA2024-T3 Friction Stir Welding Process for Residual Stress Evaluation, Including Softening Effects

In the present paper, a numerical finite element model of the precipitation hardenable AA2024-T3 aluminum alloy, consisting of a heat transfer analysis based on the Thermal Pseudo Mechanical model for heat generation, and a sequentially coupled quasi-static stress analysis is proposed. Metallurgical softening of the material is properly considered and included in the calculations by means of the Myhr and Grong model, implemented as a user subroutine in ABAQUS. Numerical outcomes are compared with experimental results, highlighting the intriguing predictive capabilities of the model for both temperatures and residual stresses. The contour method is employed to map the longitudinal residual stress distribution on a transverse cross section of the joint. The influence of the applied boundary conditions and of the release of the clamping system on residual stresses is also assessed.

Integrated FEM-DBEM Simulation of Crack Propagation in AA2024-T3 FSW Butt Joints Considering Manufacturing Effects

This paper deals with a numerical and experimental investigation on the influence of residual stresses on fatigue crack growth in AA2024-T3 friction stir welded butt joints. An integrated FEM-DBEM procedure for the simulation of crack propagation is proposed and discussed. A numerical FEM model of the welding process of precipitation hardenable AA2024-T3 aluminum alloy is employed to infer the process induced residual stress field. The reliability of the FEM simulations with respect to the induced residual stresses is assessed comparing numerical outcomes with experimental data obtained by means of the contour method. The computed stress field is transferred to a DBEM environment and superimposed to the stress field produced by a remote fatigue traction load applied on a friction stir welded cracked specimen. Numerical results are compared with experimental data showing good agreement and highlighting the predictive capability of the proposed method. Furthermore, the influence of the residual stress distribution on crack growth is evidenced.

Modelling the deformations during the manufacturing of nanostructures on non-planar surfaces for injection moulding tool inserts

This paper presents a new manufacturing process for transferring nanostructures from a glass wafer to a curved aluminium insert for polymer injection moulding. A nanostructure consisting of sinusoidal cross-gratings with a period of 426 nm is successfully transferred to hemispheres with different radii via an embossing process. The embossing is done into a glass-like resist called HSQ, using a 50 μm thick nickel foil, manufactured with electroforming. During the imprinting process the nickel foil is stretched due to the curved surface of the aluminium substrate and it is experimentally possible to characterize this stretch by counting the periods of the cross-gratings via SEM characterization. A numerical model for simulating the deformation of the nickel foil during nanoimprint is also developed, utilizing non-linear material and geometrical behaviour. Good agreement between measured and numerically calculated stretch ratios on the surface of the deformed nickel foil is shown, and from the model it is also possible to predict the limiting boundary of the nanostructures on the curved surfaces, with decreasing radii.

Modelling the deformation of nickel foil during manufacturing of nanostructures on injection moulding tool inserts

In the present work, a manufacturing process for transferring nanostructures from a glass wafer, to a double-curved insert for injection moulding is demonstrated. A nanostructure consisting of sinusoidal cross-gratings with a period of 426 nm is successfully transferred to hemispheres on an aluminium substrate with three different radii; 500 µm, 1000 µm and 2000 µm, respectively. The nanoimprint is performed using a 50 µm thick nickel foil, manufactured using electroforming. During the imprinting process, the nickel foil is stretched due to the curved surface of the aluminium substrate. Experimentally, it is possible to address this stretch by counting the periods of the cross-gratings via SEM characterization. A model for the deformation of the nickel foil during nanoimprint is developed, utilizing non-linear material and geometrical behaviour. Good agreement between measured and numerically calculated stretch ratios on the surface of the deformed nickel foil is found, and it is shown, that from the mode...

Defining allowable physical property variations for high accurate measurements on polymer parts

Measurement conditions and material properties have a significant impact on the dimensions of a part, especially for polymers parts. Temperature variation causes part deformations that increase the uncertainty of the measurement process. Current industrial tolerances of a few micrometres demand high accurate measurements in non-controlled ambient. Most of polymer parts are manufactured by injection moulding and their inspection is carried out after stabilization, around 200 hours. The overall goal of this work is to reach ±5μm in uncertainty measurements a polymer products which is a challenge in today‘s production and metrology environments. The residual deformations in polymer products at room temperature after injection molding are important when micrometer accuracy needs to be achieved. Numerical modelling can give a valuable insight to what is happening in the polymer during cooling down after injection molding. In order to obtain accurate simulations, accurate inputs to the model are crucial. In rea...

Thermomechanical Modelling of Direct-Drive Friction Welding Applying a Thermal Pseudo Mechanical Model for the Generation of Heat

In the present work a 2D axisymmetric thermomechanical model of the direct-drive friction welding process is developed, taking the temperature dependent shear yield stress into account in the description of the heat generation, utilizing a recent thermal pseudo mechanical model originally developed for the friction stir welding (FSW) process. The model is implemented in ABAQUS/Explicit via a subroutine. The application in this case is joining of austenitic stainless steel rods with an outer diameter of 112 mm, used for manufacturing of exhaust gas valves for large two stroke marine engines. The material properties in terms of the temperature dependent flow stress curves used both in the thermal and the mechanical constitutive description are extracted from compression tests performed between 20 °C and 1200°C on a Gleeble 1500 thermomechanical simulator. Comparison between measured and simulated transient temperatures shows relatively good agreement and furthermore, the simulated deformations in terms of upsetting length and flash formation are also in good agreement with the observations from the experiment.

Multiphysics modelling of manufacturing processes: A review:

Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. On the other hand, processes which inherently may seem multiphysical by nature might sometimes be modelled by considerably simpler models if the problem at hand can be somehow adequately simplified. In the present article, examples of this will be presented. The cases are chosen with the aim of showing the diversity in the field of modelling of manufacturing processes as regards process, materials, generic disciplines as well as length scales: (1) modelling of tape casting for thin ceramic layers, (2) modelling the flow of polymers in extrusion, (3) modelling the deformation process of flexible stamps for nanoimprint lithography, (4) modelling manufacturing of composite parts and (5) modelling the selective laser melting process. For all five examples, the emphasis is on modelling results as well as describing the models in brief mathematical details. Alongside with relevant references to the original work, proper comparison with experiments is given in some examples for model validation.

Effect of geometry in frequency response modeling of nanomechanical resonators

The trend towards nanomechanical resonator sensors with increasing sensitivity raises the need to address challenges encountered in the modeling of their mechanical behavior. Selecting the best approach in mechanical response modeling amongst the various potential computational solid mechanics methods is subject to controversy. A guideline for the selection of the appropriate approach for a specific set of geometry and mechanical properties is needed. In this study, geometrical limitations in frequency response modeling of flexural nanomechanical resonators are investigated. Deviation of Euler and Timoshenko beam theories from numerical techniques including finite element modeling and Surface Cauchy-Born technique are studied. The results provide a limit beyond which surface energy contribution dominates the mechanical behavior. Using the Surface Cauchy-Born technique as the reference, a maximum error on the order of 50 % is reported for high-aspect ratio resonators.

Multiscale coupling based on quasicontinuum method in nanowires at finite temperatures

Nanoelectromechanical systems have been developed for ultra-high frequency oscillators because of their small size and excellent material properties. Using flexural modes and electrothermal features in nanowires for frequency tuning necessitates a sound modeling approach. The quasicontinuum method was developed to link atomistic models with the continuum finite element method in order to study the material behavior across multiple length scales. These significant efforts to develop a continuum theory based on atomistic models have so far been limited to zero temperature. The purpose of this work is to develop the theoretical framework needed to study the mechanical response in nanoscale components such as nanowires at finite temperatures. This is achieved up to a temperature of 1000 K by integrating Engineering Molecular Mechanics and the Cauchy-Born hypothesis. The proposed method is verified with Molecular Dynamics and Molecular Mechanics simulations reported in literature. Bending properties of nanowires at finite temperatures were studied with the proposed method. Thermomechanical properties were investigated by including surface effects.

Comparison of residual stresses in sand- and chill casting of ductile cast iron wind turbine main shafts

In this work, simulations of pouring, solidification and cooling, and residual stress evolution of sand and chill cast wind turbine main shafts is performed. The models are made in the commercial software MAGMAsoft. As expected, the cooling rate of the sand casting is shown to be much lower than for the chill casting, resulting in a very course microstructure. From the simulations the nodule count is found to be 17 nodules per mm2 and 159 nodules per mm2 for the sand and chill casting, respectively, in the critical region of the main bearing seat. This is verified from nodule counts performed on the real cast main shafts. Residual stress evaluations show an overall increase of the maximum principal stress field for the chill casting, which is expected. However, the stresses are found to be in compression on the surface of the chill cast main shaft, which is unforeseen.