A method for prediction of unstable deformation in hot forging process by simulation

A method is proposed for prediction of the unstable deformation in hot forging process using both the determined thermomechnical parameter windows of the unstable deformation zones and finite element simulation. Taking Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy as the testing material, the thermomechnical parameter windows of the unstable deformation zones for the Ti-alloy are integrated into a commercial finite element simulation software platform. The distribution and variation of the unstable deformation zones of the alloy in hot compression process are simulated and predicted using the tailor-made finite element codes in the finite element platform. The simulation results tally with the physical experiments and the proposed method for simulation and prediction of the unstable deformation is thus verified and its efficiency is validated.

Hot compression deformation behavior of the Mg-Al-Y-Zn magnesium alloy

The hot deformation behavior of a Mg-Al-Y-Zn magnesium alloy was investigated by hot compressive testing on a Gleeble-1500 thermal simulator at the temperature ranging from 523 to 673 K with the strain rate varying from 0.001 to 1 s^-1. The relationships among flow stress, strain rate, and deformation temperature were analyzed, and the deformation activation energy and stress exponent were calculated. Microstructure evolution of the alloy under different conditions was examined. The results indicated that the maximum value of the flow stress increased with the decrease of deformation temperature or the increase of strain rate. Under the present deformation conditions, dynamic recrystallization （DRX） occurred in the alloy, which was the main softening mechanism during deformation at elevated temperature. The deformation temperature and strain had significant effects on the microstructure of the alloy.

Complicated deformation simulating on temperature-driven 4D printed bilayer structures based on reduced bilayer plate model

The four-dimensional(4D) printing technology, as a combination of additive manufacturing and smart materials, has attracted increasing research interest in recent years. The bilayer structures printed with smart materials using this technology can realize complicated deformation under some special stimuli due to the material properties.The deformation prediction of bilayer structures can make the design process more rapid and thus is of great importance. However, the previous works on deformation prediction of bilayer structures rarely study the complicated deformations or the influence of the printing process on deformation. Thus, this paper proposes a new method to predict the complicated deformations of temperature-sensitive 4D printed bilayer structures,in particular to the bilayer structures based on temperature-driven shape-memory polymers(SMPs) and fabricated using the fused deposition modeling(FDM) technology. The programming process to the material during printing is revealed and considered in the simulation model. Simulation results are compared with experiments to verify the validity of the method. The advantages of this method are stable convergence and high efficiency,as the three-dimensional(3D) problem is converted to a two-dimensional(2D) problem.The simulation parameters in the model can be further associated with the printing parameters, which shows good application prospect in 4D printed bilayer structure design.

HOT DEFORMATION CHARACTERISTICS AND MICROSTRUCTURE DEVELOPMENT OF Ti-6AI-4V BAR UNDER FORGING CONDITIONS

The uniformity of microstructure distribution across the transverse section of a Ti-6AI-4 V bar afler stepwise radial forging process is a relevant index to the quality of the foaled bar. In this work, hot deformation chamcteristics of Ti-6Al-4 V bar in the stepwise radial forging process were investigated in the or+p and g range 6etween 940℃ and 1000℃. Various flow curves and microstructures were obtained by using Gleeble simulation. The deformation process of a bar from initial diameter to a desired reduction in cross section was simulated by using a FEM code ABAQUS combined with the constitutive models obtained from physical simulation. Heat onduction model was coupled to the computation. The principal stresses and final strain istribution of the bar after forging were predicted by the contours obtained from FEM analysis. Together with the results obtained from Gleeble simulation, a map of microstructure distribu- tion on the cross section of the forged bar was constructed. According to the map,recrystallized zone in the center region of the bar was predicted to be approximately 50 to 65% of the total cross section area.

Numerical simulation of influences of the earth medium's lateral heterogeneity on co- and post-seismic deformation

Many studies revealed that the Earth medium＇s lateral heterogeneity can cause considerable effects on the co- and post-seismic deformation field. In this study, the threedimensional finite element numerical method are adopted to quantify the effects of lateral heterogeneity caused by material parameters and fault dip angle on the co- and postseismic deformation in the near- and far-field. Our results show that： 1） the medium＇s lateral heterogeneity does affect the co-seismic deformation, with the effects increasing with the medium＇s lateral heterogeneity caused by material parameters; 2） the Lame parameters play a more dominant role than density in the effects caused by lateral heterogeneity; 3） when a fault＇s dip angle is smaller than 90, the effects of the medium＇s lateral heterogeneity on the hanging wall are greater than on the footwall; 4） the impact of lateral heterogeneity caused by the viscosity coefficient on the post-seismic deformation can affect a large area, including the near- and far-field.

Simulation of bulk metal forming processes using one-step finite element approach based on deformation theory of plasticity

The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.

SIMULATION OF EXTRA LIGHT-THIN COMPONENT DEFORMATION WITH ABNORMAL SHAPE

Based on the analyses of the structural feature and the function requirements of newstyle bottle cap, the two fundamental components, the lining washer and the outer body, are abstracted as a plate and a cylinder with thin wall respectively. For simulating the deformation of the lining washer under equiaxial pressure, the modified Lagrangian finite element analysis is applied on the 228 triangular elements. Under assembly pressure, the plastoelastic deformation of both the lining washer and the outer body are studied in terms of Tresca＇s yield criterion and the limitation of the plastic deformation is presented when the two components are assembled into one unit. For the production of this kind of bottle cover, experiments are carried out by carefully measuring the changes of the diameter of lining washer as well as that of the outer body. It is shown that results from the experiments have a good agreement with the theoretical calculation and the maximum value of the allowable pressure has successfully been used in the design of newly developed bottle cap production system.

Computer Simulation of Plastic Deformation in GrainBoundary Region under High Rate Loading

The computer simulation of Al three-dimensional crystallite containing grain boundary of special type was carried out and its behaviour under high rate loading was investigated. The molecular dynamics method was used and interaction betwen atoms was described based on pseudopotential method. Vortical character of the atom movements in the grain boundary region is realized under shear loading in certain directions. Back and forth movements of atoms in the direction which is perpendicular to the shear also arise. Amplitude of such movements is approximately equal to an interplanar distance in this direction.

Molecular Dynamics Simulations of the Orientation Effect on the Initial Plastic Deformation of Magnesium Single Crystals

Molecular dynamics simulation is employed to study the tension and compression deformation behaviors of magnesium single crystals with different orientations.The angle between the loading axis and the basal direction ranges from 0° to 90°.The simulation results show that the initial defects usually nucleate at free surfaces,but the initial plastic deformation and the subsequent microstructural evolutions are various due to different loading directions.The tension simulations exhibit the deformation mechanisms of twinning,slip,crystallographic reorientation and basal/prismatic transformation.The twinning,crystallographic reorientation and basal/prismatic transformation can only appear in the crystal model loaded along or near the a-axis or c-axis.For the compression simulations,the basal,prismatic and pyramidal slips are responsible for the initial plasticity,and no twinning is observed.Moreover,the plastic deformation models affect the yield strengths for the samples with different orientations.The maximum yield stresses for the samples loaded along the c-axis or a-axis are much higher than those loaded in other directions.

Research and application of schemes for constructing concrete pillars in large section finishing cut in backfill coal mining

Based on the technology of controlling surrounding rock deformation by constructing concrete pillars in large section finishing cut in backfill coal mining, the characteristics of vertical stress on concrete pillars and main factors influencing pillar stability are analyzed. By building a Winkler elastic foundation mechanical model for the support system constituted of coal pillar, backfill body and concrete pillars, mechanical calculation on stability of concrete pillar is carried out to evaluate the pillar stability and safety. Seven numeral models in three schemes with different pillar sizes, inter-row distances and compression ratios at the stopes were analyzed through numerical simulation according to width reduction principle. The practice of finishing cut at IIIB44 workface at Yangzhuang coal mine shows that： when the actual compression ratio is 86.5%, construction size inside the finishing cut is 2000 mm x 2000 mm and the interval between concrete pillars is 2000 mm x 2000 mm, the pillars can be stable with the maximum movement of two sides of each pillar being only 83 mm and 54 mm, which achieves the expected effect.

Physical Model of Drying Shrinkage of Recycled Aggregate Concrete

We prepared concretes（RC0, RC30, and RC100） with three different mixes. The poresize distribution parameters of RAC were examined by high-precision mercury intrusion method（MIM） and nuclear magnetic resonance（NMR） imaging. A capillary-bundle physical model with random-distribution pores（improved model, IM） was established according to the parameters, and dry-shrinkage strain values were calculated and verified. Results show that in all pore types, capillary pores, and gel pores have the greatest impacts on concrete shrinkage, especially for pores 2.5-50 and 50-100 nm in size. The median radii are 34.2, 31, and 34 nm for RC0, RC30, and RC100, respectively. Moreover, the internal micropore size distribution of RC0 differs from that of RC30 and RC100, and the pore descriptions of MIM and NMR are consistent both in theory and in practice. Compared with the traditional capillary-bundle model, the calculated results of IM have higher accuracy as demonstrated by experimental verifi cation.

Real-time Volume Preserving Constraints for Volumetric Model on GPU

This paper presents a parallel method for simulating real-time 3D deformable objects using the volume preservation mass-spring system method on tetrahedron meshes.In general,the conventional mass-spring system is manipulated as a force-driven method because it is fast,simple to implement,and the parameters can be controlled.However,the springs in traditional mass-spring system can be excessively elongated which cause severe stability and robustness issues that lead to shape restoring,simulation blow-up,and huge volume loss of the deformable object.In addition,traditional method that uses a serial process of the central processing unit(CPU)to solve the system in every frame cannot handle the complex structure of deformable object in real-time.Therefore,the first order implicit constraint enforcement for a mass-spring model is utilized to achieve accurate visual realism of deformable objects with tough constraint error.In this paper,we applied the distance constraint and volume conservation constraints for each tetrahedron element to improve the stability of deformable object simulation using the mass-spring system and behave the same as its real-world counterparts.To reduce the computational complexity while ensuring stable simulation,we applied a method that utilizes OpenGL compute shader,a part of OpenGL Shading Language(GLSL)that executes on the graphic processing unit(GPU)to solve the numerical problems effectively.We applied the proposed methods to experimental volumetric models,and volume percentages of all objects are compared.The average volume percentages of all models during the simulation using the mass-spring system,distance constraint,and the volume constraint method were 68.21%,89.64%,and 98.70%,respectively.The proposed approaches are successfully applied to improve the stability of mass-spring system and the performance comparison from our experimental tests also shows that the GPU-based method is faster than CPU-based implementation for all cases.

Microstructure-based Simulation of Plastic Deformation Behavior of SiC Particle Reinforced Al Matrix Composites

This article, in order to unearth the deformation mechanism of particle reinforced metal matrix composites, establishes a finite element model （FEM） based on the actual microstructures. It finds out and analyzes the distribution of von Mises effective stress, strain and the maximum principal stress in the matrix and particles. Moreover, the overall stress and strain in the matrix and composites are calculated. By comparison, a tiny discrepancy exists between the experimental results and the simulation with respect to flow stresses. The effects of deformation parameters, such as temperature and strain rate, on the strengthening mechanism are explored and proved to be weak.

Microstructure Evolution of Different Forging Processes for12%Cr Steel During Hot Deformation

Five forging experiments were designed and conducted to investigate the effect of process parameters on microstructure evolution during hot deformation for X12CrMoWVNbN10-1-1 steel.The experimental results indicated that average grain size became finer with the increasing number of upsetting and stretching.Especially,the size of stretching three times with upsetting twice had the most remarkable effect on refinement,and the size was only 27.36%of the original one.Moreover,the stress model was integrated into the software and finite element models were established.Simulation results demonstrated that the strain at center point of workpiece was far larger than critical strain value in each process,so that dynamic recrystallization(DRX) occurred in each workpiece,which implied DRX could occur for several times with the increasing number of upsetting and stretching,and uniform finer microstructure would be obtained.However,the results also showed that higher temperature was an unfavorable factor for grain refinement,so the times of heating should be limited for workpiece,and as many forging processes as possible should be finished in once heating.

Numerical simulation of shock wave interaction with a deformable particle based on the pseudo arc-length method

In this paper, we combine the pseudo arc-length numerical method with the mathematical model of multiphase compressible flow for simulating the shock wave interaction with a deformable particle. Firstly, an arc-length parameter is introduced to weaken the discontinuous singularity of governing equations, and an efficient pseudo arc-length numerical method of multiphase compressible flow is proposed. Then the accuracy and adaptive moving mesh property of this algorithm are tested. Finally, the multiphase pseudo arc-length numerical method is applied to the problem of interaction between shock wave and the deformable particle. Through the flow flied change and data analysis of key points, it can be found the complex wave structures are presented after the interactions between the planar incident shock wave and the metal particle, and all these wave interactions lead to the movement and deformation of metal particle, and then the deformed particle will affect the transmitted shock wave back. According to the discussion, the deformation of particle and shock wave propagation in the particle are determined by the shock wave impedance of each medium and shock speed, so the interaction between shock wave and the deformable particle can be studied on the basis of physical properties of explosive mediums.

Computational fluid dynamics simulation of friction stir welding:A comparative study on different frictional boundary conditions

Numerical simulation based on computational fluid dynamics （CFD） is a useful approach for quantitatively investigating the underlying thermal-mechanical conditions during FSW, such as temperature field and material deformation field. One of the critical issues in CFD simulation of FSW is the use of the frictional boundary condition, which represents the friction between the welding tool and the workpiece in the numerical models. In this study, three-dimensional numerical simulation is conducted to analyze the heat transfer and plastic deformation behaviors during the FSW of AA2024. For comparison purposes, both the boundary velocity （BV） models and the boundary shear stress （BSS） models are employed in order to assess their performances in predicting the temperature and material deformation in FSW. It is interesting to note that different boundary conditions yield similar predictions on temperature, but quite different predictions on material deformation. The numerical predictions are compared with the experimental results. The predicted deformation zone geometry by the BSS model is consistent with the experimental results while there is large difference between the predictions by the BV models and the experimental measurements. The fact that the BSS model yields more reasonable predictions on the deformation zone geometry is attributed to its capacity to automatically adjust the contact state at the tool/workpiece interface. Based on the favorable predictions on both the temperature field and the material deformation field, the BSS model is suggested to have a better performance in numerical simulation of FSW than the BV model.

DESIGN AND IMPLEMENTATION OF REAL-TIME PHYSICS SIMULATION ENGINE FOR e-ENTERTAINMENT

We present our recent research results regarding the designing and implementation of real-time physics simulation engines,which aim at developing physics-inspired e-entertainment such as computer games,mobile applications,interactive TV and other smart media in Korea.Our real-time physics engine consists of three functional components:rigid body dynamics simulation,deformable body simulation,and data-driven physics simulation.The core simulation techniques to realize these simulation components include real-time collision detection and response,large-scale model simulation,and character model control.In this paper,we highlight these features and demonstrate their performances.We also showcase some of the gaming applications that we have integrated our physics engine into.