FLOW STRESS MODELING FOR AERONAUTICAL ALUMINUM ALLOY 7050-T7451 IN HIGH-SPEED CUTTING

The high temperature split Hopkinson pressure bar （SHPB） compression experiment is conducted to obtain the data relationship among strain, strain rate and flow stress from room temperature to 550 C for aeronautical aluminum alloy 7050-T7451. Combined high-speed orthogonal cutting experiments with the cutting process simulations, the data relationship of high temperature, high strain rate and large strain in high-speed cutting is modified. The Johnson-Cook empirical model considering the effects of strain hardening, strain rate hardening and thermal softening is selected to describe the data relationship in high-speed cutting, and the material constants of flow stress constitutive model for aluminum alloy 7050-T7451 are determined. Finally, the constitutive model of aluminum alloy 7050-T7451 is established through experiment and simulation verification in high-speed cutting. The model is proved to be reasonable by matching the measured values of the cutting force with the estimated results from FEM simulations.

Constitutive equations for high temperature flow stress prediction of 6063 Al alloy considering compensation of strain

In order to develop the appropriate constitutive equation which can precisely model high temperature flow stress of 6063 Al alloy, a series of isothermal hot compression tests were performed at temperatures from 573 to 773 K and strain rates from 0.5 to 50 s?1 on a Gleeble?1500 thermo-simulation machine. Zener–Hollomon parameter in an exponent-type equation was used to describe the combined effects of temperature and strain rate on hot deformation behaviour of 6063 Al alloy, whereas the influence of strain was incorporated in the developed constitutive equation by considering material constants (α,n,Q andA) to be 4th order polynomial functions of strain. The results show that the developed constitutive equation can accurately predict high temperature flow stress of 6063 Al alloy, which demonstrates that it can be suitable for simulating hot deformation processes such as extrusion and forging, and for properly designing the deformation parameters in engineering practice.

Effect of flow stress—strain relation on forming limit of 5754O aluminum alloy

A modified Swift type flow stress—strain relation was presented in order to describe the uniaxial tension test curve reasonably. The FLD-strain （forming limit diagram made up of limit strain） of 5754O aluminum alloy sheet was calculated based on the two flow stress—strain relations using Yld2000-2d yield function. By comparing the theoretical and experimental results, it is found that the calculated FLD-strain based on the modified Swift flow stress—strain relation can reasonably describe the experimental results. However, though the common Voce flow stress—strain relation can describe the deformation behavior during homogenous deformation phase accurately, the FLD-strain calculated based on it is obviously lower than the experimental result. It is concluded that the higher the hardening rate of sheet metal is, the higher the forming limit is. A method for determining the reasonable flow stress—strain relation is recommended for describing the material behavior during inhomogenous phase and the forming limit of sheet metal.

Prediction of flow stress of Mg-Nd-Zn-Zr alloy during hot compression

Isothermal hot compression tests were carried out on Mg-3.0Nd-0.2Zn-0.4Zr （mass fraction, %, NZ30K） alloy using a Gleeble-3500 thermo-simulation machine at temperatures ranging from 350 to 500 ℃and strain rates from 0.001 to 1 s^-1. A correction of flow stress for deformation heating at a high strain rate was carried out. Based on the corrected data for deformation heating, a hyperbolic sine constitutive equation was established. The constants in the constitutive equation of the hyperbolic sine form were determined as a function of strain. The flow stresses predicted by the developed equation agree well with the experimental results, which confirms that the developed constitutive equations can be used to predict the flow stress of NZ30K alloy during hot deformation.

PREDICTION OF FLOW STRESS OF HIGH-SPEED STEEL DURING HOT DEFORMATION BY USING BP ARTIFICIAL NEURAL NETWORK

The hot deformation behavior of TI (18W-4Cr-1V) high-speed steel was investigated by means of continuous compression tests performed on Gleeble 1500 thermomechan- ical simulator in a wide range of tempemtures (950℃-1150℃) with strain rotes of 0.001s-1-10s-1 and true strains of 0-0. 7. The flow stress at the above hot defor- mation conditions is predicted by using BP artificial neural network. The architecture of network includes there are three input parameters:strain rate,temperature T and true strain , and just one output parameter, the flow stress ,2 hidden layers are adopted, the first hidden layer includes 9 neurons and second 10 negroes. It has been verified that BP artificial neural network with 3-9-10-1 architecture can predict flow stress of high-speed steel during hot deformation very well. Compared with the prediction method of flow stress by using Zaped-Holloman parumeter and hyperbolic sine stress function, the prediction method by using BP artificial neurul network has higher efficiency and accuracy.

Establishment and application of flow stress models of Mg-Y-MM-Zr alloy

The hot working behaviors of Mg-9Y-1MM-0.6Zr （WE91） magnesium alloy were researched in a temperature range of 653 773 K and strain rate range of 0.001 1 s 1 on Gleeble 1500D hot simulator under the maximum deformation degree of 60%. A mathematical model was established to predict the stress—strain curves of this alloy during deformation. The experimental results show that the relationship between stress and strain is obviously affected by the strain rates and deformation temperatures. The flow stress of WE91 magnesium alloy during high temperature deformation can be represented by Zener-Hollomon parameter in the hyperbolic Arrhenius-type equation, and the stress—strain curves obtained by the established model are in good agreement with the experimental results,which prove that the model reflects the real deformation characteristics of the WE91 alloy. The average deformation activation energy is 220 kJ/mol at strain of 0.1. The microstructures of WE91 during deformation processing are influenced by temperature and strain rates.

Flow stress behavior and processing map of extruded 7075Al/SiC particle reinforced composite prepared by spray deposition during hot compression

Hot compression tests of the extruded 7075Al/15%SiC (volume fraction) particle reinforced composite prepared by spray deposition were performed on Gleeble?1500 system in the temperature range of 300?450 °C and strain rate range of 0.001?1 s?1. The results indicate that the true stress?true strain curve almost exhibits rapid flow softening phenomenon without an obvious work hardening, and the stress decreases with increasing temperature and decreasing strain rate. Moreover, the stress levels are higher at temperature below 400 °C but lower at 450 °C compared with the spray deposited 7075Al alloy. Superplastic deformation characteristics are found at temperature of 450 °C and strain rate range of 0.001?0.1 s?1 with corresponding strain rate sensitivity of 0.72. The optimum parameters of hot working are determined to be temperature of 430?450 °C and strain rate of 0.001?0.05 s?1 based on processing map and optical microstructural observation.

BEHAVIOR OF FLOW STRESS OF ALUMINUM SHEETS USED FOR PRESSURE CAN DURING COMPRESSION AT ELEVATED TEMPERATURE

The behavior of flow stress of Al sheets used for pressure can prepared by different melt-treatment during plastic deformation at elevated temperature was studied by isothermal compression test using Gleeble1500 dynamic hot-simulation testing machine. The results show that the AI sheets possess the remarkable characteristic of steady state flow stress when they are deformed in the temperature range of 350-500℃ at strain rates within the range of 0.01-10.0s^-1. A hyperbolic sine relationship is found to correlate well the flow stress with the strain rate, and an Arrhenius relationship with the temperature, which implies that the process of plastic deformation at elevated temperature for this material is thermally activated. Compared with the AI pieces prepared by no or conventional melt-treatment, hot deformation activation energy of AI sheets prepared by high-efficient melt-treatment is the smallest （ Q= 168.0kJ/mol）, which reveals that the hot working formability of this material is very better, and has directly to do with the effective improvement of its metallurgical quality.

A FLOW STRESS MODEL FOR AZ61 MAGNESIUM ALLOY

The flow stress behaviors of AZ61 alloy has been investigated at temperature rangefrom 523 to 673K with the strain rates of 0.001-1s^(-1). It is found that the averageactivation energy, strain rate sensitive exponent and stress exponent are different atvarious deformation conditions changing from 143.6 to 176.3kJ/mol, 0.125 to 0.167and 6 to 8 respectively. A flow stress model for AZ61 alloy is derived by analyzingthe stress data based on hot compression test. It is demonstrated that the flow stressmodel including strain hardening exponent and strain softening exponent is suitableto predicate the flow stress. The prediction of the flow stress of AZ61 alloy has shownto be good agreement with the test data. The maximum differences of the peak stressescalculated by the model and obtained by experiment is less than 8%.

Flow stress prediction of Hastelloy C-276 alloy using modified Zerilli−Armstrong,Johnson−Cook and Arrhenius-type constitutive models

To better understand the hot deformation behaviors of Hastelloy C-276 alloy under elevated temperatures,hot tensile tests were carried out in the temperature range of 1223−1423 K and the strain rate range of 0.01−10 s^−1,respectively.Based on the modified Zerilli−Armstrong,modified Johnson-Cook,and strain-compensated Arrheniustype models,three constitutive equations were established to describe the high-temperature flow stress of this alloy.Meanwhile,the predictability of the obtained models was evaluated by the calculation of correlation coefficients(r)and absolute errors(Δ),where the values of r for the modified Zerilli−Armstrong,Johnson−Cook,and Arrhenius-type constitutive models were computed to be 0.935,0.968 and 0.984,and the values ofΔwere calculated to be 13.4%,10.5%and 6.7%,respectively.Moreover,the experimental and predicted flow stresses were compared in the strain range of 0.1−0.5,the results further indicated that the obtained modified Arrhenius-type model possessed better predictability on hot flow behavior of Hastelloy C-276.

Influence of temperature and strain rate on flow stress behavior of twin-roll cast, rolled and heat-treated AZ31 magnesium alloys

The effects of temperature and strain rate on the flow stress behavior of twin-roll cast, rolled and heat-treated AZ31 magnesium alloys were investigated under uniaxial tension. At high temperatures, dynamic recovery, continuous dynamic recrystallization, grain boundary sliding and the activation of additional slip systems lead to an improvement of the ductility of the alloys. The elongation to failure is nearly independent of the strain rate between 473 and 523 K at 10-2 s-1 and 10-1 s-1, which is related to the strain rate dependence of the critical resolved shear stress（CRSS） for nonbasal slip. Despite the high temperature, twins are even observed at 573 K and 10-3 s-1 because they have a low CRSS.

Size effects on flow stress of C3602 in cylinder compression with different lubricants

Micro parts are more difficult to be formed than macro parts because of size effects. The size effects on the flow stress of copper alloy C3602 with different lubricants were studied. Specimens were heat treated at 350℃ for 1 h and 700℃ for 3 h in nitrogen atmosphere, respectively. The initial diameters of the specimens were varied from 5 to 1 mm with a height-to-diameter ratio h0/D0 = 1.5. Cylinder compression was carried out in the lubrication condition with talc powder, without lubricant, with petroleum jelly, and with vegetable oil. The experiment was carried out at room temperature on a universal testing machine INSTRON 5569 with a strain rate of ε = 0.0025 A. The results show that with the same lubricant, the yield strength decreases with a decrease in specimen size for the specimens annealed at 350℃ for 1 b; however, it increases with a decrease in specimen size for the specimens annealed at 700℃ for 3 h. The yield strength decreases with an increase in grain size. The influences of lubricants on yield strength become larger with miniaturization of the specimens.

Microstructural evolution,flow stress and constitutive modeling of Al−1.88Mg−0.18Sc−0.084Er alloy during hot compression

To explore the hot compression behavior and microstructural evolution,fine-grained Al−1.88Mg−0.18Sc−0.084Er(wt.%)aluminum alloy wires were fabricated with Castex(continuous casting−extrusion)and ECAP-Conform,and their hot compression behavior was investigated at temperatures of 673−793 K and strain rates of 0.001−10 s−1;the microstructures were characterized by optical microscope,X-ray diffractometer,transmission electron microscope,and electron backscattered diffractometer,and the flow stresses were obtained by thermal compression simulator.Microstructural evolution and flow curves reveal that dynamic recovery is the dominant softening mechanism.Continuous dynamic recrystallization followed by dynamic grain growth takes place at a temperature of 773 K and a strain rate of 0.001 s−1;the yielding drop phenomenon was discovered.Hyperbolic sine constitutive equation incorporating dislocation variables was presented,and a power law constitutive equation was established.The stress exponent is 3.262,and the activation energy for deformation is 154.465 kJ/mol,indicating that dislocation viscous glide is the dominant deformation mechanism.

Hot deformation behaviors and flow stress model of GCr15 bearing steel

The hot deformation behaviors of GCr15 bearing steel were investigated by isothermal compression tests, performed on a Gleeble-3800 thermal-mechanical simulator at temperatures between 950 ℃ and 1 150 ℃ and strain rates between 0.1 and 10 s-1. The peak stress and peak strain as functions of processing parameters were obtained. The dependence of peak stress on strain rate and temperature obeys a hyperbolic sine equation with a Zener-Hollomon parameter. By regression analysis, in the temperature range of 950-1 150 ℃ and strain rate range of 0.1?10 s?1, the mean activation energy and the stress exponent were determined to be 351kJ/mol and 4.728, respectively. Meanwhile, models of flow stress and dynamic recrystallization (DRX) grain size were also established. The model predictions show good agreement with experimental results.

Effects of specimen size on flow stress of micro rod specimen

With the miniaturization of parts,size effects occur in the micro-forming processes.To investigate the effects of the specimen size on the flow stress,a series of upsetting deformation experiments were carried out at room temperature for specimens with different diameters.And the grain size of billets was changed by anneal processes to analyze the grain size effects on the size dependence of flow stress.The deviation of stress was observed.The results show that the flow stress decreases with decreasing billet dimensions.As the dislocation accumulation in free surface layer is slight,the reduction degree of flow stress becomes larger when the plastic deformation goes on.The flow stress is enlarged by grain size,which can be analyzed by the grain boundary length per area.The deviation increases with decreasing specimen size.This can be explained by the effects of grain orientation stochastic distribution according to the Schmid law.As a result,the micro-forming process must be considered from the viewpoint of polycrystalline structure,and the single grains of micro-billet dominate the deformation.

Microstructure evolution and its effect on flow stress of TC17 alloy during deformation in α+β two-phase region

The microstructure evolution and its effect on flow stress of TC17 alloy during deformation in the α+β two-phase region were investigated via microstructure characterization and isothermal compression tests. Results showed that the spheroidized rate of α phase at 820 and 850℃ slightly increased with increasing strain. With increasing deformation temperature, the spheroidized rate of α phase showed a slight increasing trend, but the volume fraction of α phase significantly decreased. The flow stress at 780 ℃ and 1 s^-1 decreased continuously and steady state condition was not achieved up to strain of 1.2 due to dislocation annihilation and α lamellae rotation. Under this condition, the dynamic spheroidization was retarded. At the deformation temperatures of 820 and 850℃, and a strain rate of 1 s^-1, a steady state flow stress was observed at strains above 0.8 due to the balance between work hardening and dynamic softening. The dynamic softening was attributed to the α lamellae rotation, dynamic recovery and a little spheroidization.

Flow stress equation for multipass hot-rolling of aluminum alloys

A series of simple axisymmetric compression tests were carried out on the computer servo controlled Gleeble 1 500 machine when strain rates ranged between 0.05 25 s -1 and deformation temperature 300 500 ℃. The results show that flow stress is related to the Zener Hollonom parameter Z and strain, as well as the static recrystallization fraction between passes during multipass hot deformation of 5182 aluminum alloy. Hence, a modified exponential flow stress equation was presented by considering the values of ln A and β as functions of strain, and by using the uniform softening method and incorporating the static recrystallization fraction between passes to consider the effects of residual strain during multipass hot rolling of 5182 aluminum alloy. The validity of the equation was examined by a typical non isothermal multipass deformation test.

Research on flow stress of spray formed 70Si30Al alloy under hot compression deformation

The flow stress of spray formed 70Si30Al alloy was studied by hot compression on a Gleeble- 1500 test machine. The experimental results indicated that the flow stress depends on the strain rate and the deformation temperature. The flow stress increases with an increase in strain rate at a given deformation temperature. The flow stress decreases with the deformation temperature increasing at a given strain rate. The relational expression among the flow stress, the swain rate, and the deformation temperature satisfies the Arrhenius equation. The deformation activation energy of 70Si30Al alloy during hot deformation is 866.27 kJ/mol from the Arrhenius equation.

Flow stress and dynamic recrystallization behavior of Al-9Mg-1.1Li-0.5Mn alloy during hot compression process

The flow stress behavior of spray-formed Al-9Mg-1.1Li-0.5Mn alloy was studied using thermal simulation tests on a Gleeble-3500machine over deformation temperature range of300-450℃and strain rate of0.01-10s^-1.The microstructural evolution of the alloy during the hot compression process was characterized by transmission electron microscopy(TEM)and electron back scatter diffractometry(EBSD).The results show that the flow stress behavior and microstructural evolution are sensitive to deformation parameters.The peak stress level,steady flow stress,dislocation density and amount of substructures of the alloy increase with decreasing deformation temperature and increasing strain rate.Conversely,the high angle grain boundary area increases,the grain boundary is in serrated shape and the dynamic recrystallization in the alloy occurs.The microstructure of the alloy is fibrous-like and the main softening mechanism is dynamic recovery during steady deformation state.The flow stress behavior can be represented by the Zener-Hollomon parameter Z in the hyperbolic sine equation with the hot deformation activation energy of184.2538kJ/mol.The constitutive equation and the hot processing map were established.The hot processing map exhibits that the optimum processing conditions for Al-9Mg-1.1Li-0.5Mn alloy are in deformation temperature range from380to450℃and strain rate range from0.01to0.1s^-1.

Effects of casting process on microstructures and flow stress behavior of Mg-9Gd-3Y-1.5Zn-0.8Zr semi-continuous casting billets

Mg-9Gd-3Y-1.5Zn-0.8Zr alloys own high strength,good heat and corrosion resistance.However,it is difficult for the fabrication of large-scale billets,due to the poor deformation ability and strong hot-crack tendency.This work investigated the casting process on the microstructures and flow stress behaviors of the semi-continuous casting billets for the fabrication of large-scale Mg-9Gd-3Y-1.5Zn-0.8Zr billets.The casting process(electromagnetic intensity and casting speed)shows outstanding effects on the microstructures and flow stress behavior of the billets.The billets with the specific casting process(I=68 A,V=65 mm/min)exhibit uniform microstructures and good deformation uniformity.