Elastic-plastic finite element simulation for diamond turning process

Using general commercial software, a coupled thermo-mechanical plane strain larger deformation orthogonal cutting model is developed on the basis of updated Lagrangian formulation in this paper. The workpiece is oxygen free high conductivity copper (OFHC copper), its flow stress is considered as a function of strain, strain rate and temperature to reflect its realistic changes in physical properties. In order to take into account the cutting edge radius effects of the single crystal diamond tool, rezoning technology is introduced into this simulation model. Diamond turning process is simulated from the initial stage to the steady stage of chip formation, and the distribution of temperature, equivalent stress, residual stress, strain rate and shear angle are obtained. The simulated principal force is compared with published experiment data and they are found to be in good agreement with each other, but poor for thrust force due to no consideration of elastic recovery for machined surface in the elastic-plastic material model.

A NEW NUMERICAL SCHEME FOR ELASTIC-PLASTIC SIMULATION OF EXCAVATION IN GEO-ENGINEERING

For the path dependency and nonlinearity introduced by incremental construction, numerical method has been widely used in deformation analysis of geo engineering.In the numerical simulation scheme commonly used in the past, the excavating loads are extracted from nodal stresses, which are deduced linearly from the stresses at Gauss point in finite element method.The unneglectable calculation error is contained in this process when elastic plastic constitutive model is employed.The error mentioned above is analyzed in detail.Based on the analysis of excavation process and the principle of finite element theory, a new simulation scheme for excavation is proposed.At the end of this paper, an application in rock engineering is given out.

Computer Simulation of Thermal-Mechanical Processing

Supported by the high-speed SGI engineering workstation and the general MARCTM software, a system is developed to simulate the hot deformation process and the cooling process after deformation in the forging of Cr12 steel on the basis of elastic-plastic FEM techniques with coupled thermal-mechanical-microstructural alteration. In this system, a mathematical model, obtained by plentiful physical simulation experiments on Gleeble 1500 thermomechanical simulator, is introduced to describe the changes in microstructure and properties of steels. This system is proved to be reliable to simulate the thermal field and stress field as well as the microstructure of Cr12 steel during the forging process. It can also be used to optimize and control the forging process.

NUMERICAL SIMULATION OF HOT SAWING PROCESS

The present paper gives a numerical simulation of hot sawing process by using elastic- plastic finite element method. The simulation is carried out for the moment from the beginning of deformation to the local yield in work piece. In order to treat the work hardening on deformation resistance, a correction of stress based on deformation rate is taken into consideration. The calculation results shows, there are two stress peaks both on the lower and upper sides ahead of the tooth tip during the elastic press stage, in which the displacement of tooth is below 0.735*10-6 cm. Following the push of saw tooth and rise of saw load, metal at the corner of filing reaches the yield point and a local plastic area appears,where metal shapes new filing part towards the free surface under the extrusion forces. Meanwhile the stress peaks ahead of tooth tip initial also yield regions. The displacement of saw tooth is between 0.735*10-6cm and 1.274*10-6cm in this stage. With the further push of the saw tooth, metal bounded to tooth tip is torn under the combination of tensile and sheer stress. The slide of metal and its local plastic flow form the extension of filing. Then the saw load rises no longer and static sawing procedure continues.

Plasma Simulation beyond Rigid-Macroparticle Approximation

Current mainstream method of simulating plasma is based on rigid-macroparticle approximation in which many realistic particles are merged, according to their initial space positions regardless of their initial velocities, into a macroparticle, and do a global motion. This is a distorted picture because what each macroparticle do is to break into, because of differences among velocities of contained realistic particles, pieces with different destinations at next time point, rather than a global moving to a destination at next time point. Therefore, the scientific validity of results obtained from such an approximation cannot be warranted. Here, we propose a solution to this problem. It can fundamentally warrant exact solutions of plasma self-consistent fields and hence those of microscopic distribution function.

Numerical Simulation of New Friction Welded Joints

In developing the new friction welding technology, the thermal elastic-plastic stress analysis by the finite element method was carried out to seek the suitable welding conditions such as the friction pressure, the friction speed and the upset pressure. The results obtained are as follows： Heat transfer to the specimens and the intermediate material during friction process was made clear; The operational conditions such as the rotation number of the intermediate material and the friction pressure to reach the liquidus in the interface could be estimated; Further, as the overhang length near the interface is well related to the joint efficiency, we tried to obtain the operational conditions by numerical analysis to acquire a certain length of the overhang length near the interface.

Solvent Property Induced Morphological Changes of ABA Amphiphilic Triblock Copolymer Micelles in Dilute Solution: A Self-consistent Field Simulation Study

The morphological changes of ABA amphiphilic triblock copolymer micelles in dilute solution were systematically studied by tuning the solvent property using self-consistent field simulation. The solvent property was tuned by changing the Flory-Huggins interaction parameters between each type of blocks and solvent, respectively. The simulation results show that by changing the solvent properties, a series of micelle morphologies such as vesicle, cage-like, ring-shaped, rod-like and spherical micelle morphologies can be obtained. Variations of the free energy of the solution system and the surface area of micelles with the Flory-Huggins interaction parameters were calculated to better understand the effect of solvent property on micelle morphologies. In addition, a phase diagram showing the morphological changes of micelles with the Flory-Huggins interaction parameters is provided.

COMPUTER SIMULATED ANALYSES ON DEFORMATION AND FRACTURE OF NON-CRACKED AND CRACKED SPECIMENS

A unified damage and fracture model,the combinatory work density model,which is suitable for ei- ther non-cracked body or cracked body has been suggested.In the present paper,the deformation and fracture of the two kinds of tensile spceimen and TPB specimen made of 40Cr steel have been simulated by using the new mod- el together with the large èlastic-plastic deformation finite element method.The results give a good picture of the whole deformation and fracture processes of the specimens in experiments;especially,the results on the TPB specimen can be used to obtain the relationship between load and displacement at the loading point P-Δ,and between crack ex- tension and displacement at the loading point Δα-Δ,the resistance curve J_R-Δa and the fracture toughness J_(IC).All the results are in remarkable agreement with those obtained by experiments.Therefore the model suggested here can be used to simulate crack initiation and propagation in non-cracked body and fracture initiation and crack stable propa- gation in cracked body.

Numerical Study of the Plastic Behaviour of a Low Alloy Steel during Phase Transformation

Phase transformations in steels play a major role on the generation of residual stresses and distortions during thermal processes such as welding and heat treatments. In this paper, we focus on the influence of phase transformations on the plastic behaviour of a low-alloy steel. It is now well known that the plastic strain rate can then be decomposed as the sum of two terms. The first one corresponds to classical plasticity while the second one is due to the evolution of the transformation and is usually referred to as corresponding to transformation induced plasticity. A theoretical approach of the problem has been achieved ([1][2][3]] and a macroscopic model has been proposed in the case of ideal-plastic phases. The theoretical approach has been assessed and completed using micromechanical numerical simulations but these were based on rather coarse 3D meshes due to limited computer capabilities in the 80’s. This paper presents new finite element micromechanical calculations using refined meshes to analyse the classical plastic behaviour and transformation induced plasticity. The results of the computations are discussed and compared with the calculations initially performed. Finally improvements of the macroscopic model are proposed.

SELF ASSEMBLY OF ABC TRIBLOCK COPOLYMER THIN FILMS ON A BRUSH-COATED SUBSTRATE

Self assemblies of ABC triblock copolymer thin films on a densely brush-coated substrate were investigated by using the self-consistent field theory.The middle block B and the coated polymer form one phase and the alternating phase A and phase C occur when the film is very thin either for the neutral or selective hard surface(which is opposite to the brushcoated substrate).The lamellar phase is stable on the hard surface when it is neutral and interestingly,the short block tends to stay on this hard surface...

Temperature-dependent constitutive modeling of a magnesium alloy ZEK100 sheet using crystal plasticity models combined with in situ high-energy X-ray diffraction experiment

A multiscale crystal plasticity model accounting for temperature-dependent mechanical behaviors without introducing a larger number of unknown parameters was developed.The model was implemented in elastic-plastic self-consistent(EPSC)and crystal plasticity finite element(CPFE)frameworks for grain-scale simulations.A computationally efficient EPSC model was first employed to estimate the critical resolved shear stress and hardening parameters of the slip and twin systems available in a hexagonal close-packed magnesium alloy,ZEK100.The constitutive parameters were thereafter refined using the CPFE.The crystal plasticity frameworks incorporated with the temperature-dependent constitutive model were used to predict stress–strain curves in macroscale and lattice strains in microscale at different testing temperatures up to 200℃.In particular,the predictions by the crystal plasticity models were compared with the measured lattice strain data at the elevated temperatures by in situ high-energy X-ray diffraction,for the first time.The comparison in the multiscale improved the fidelity of the developed temperature-dependent constitutive model and validated the assumption with regard to the temperature dependency of available slip and twin systems in the magnesium alloy.Finally,this work provides a time-efficient and precise modeling scheme for magnesium alloys at elevated temperatures.

Numerical Simulation on Distribution of Stress in the Electromagnetic Soft-Contact Continuous Casting Mould

A two-dimensional axisymmetric finite element model for stress distribution of billet in electromagnetic soft-contact continuous casting mould was established by a two-way coupled method.The contact state between solidified shell and mould was described to simulate the thermal-mechanical behaviors in the soft-contact mould.And the effects of frequencies and currents on stress distribution of billet had been discussed and analyzed.The results show that the equivalent stress of initial solidification shell both at its outer and inner surface decreases but at the bottom the equivalent stress of two sides of shell both increases when the current intensity is 1600 A,and the frequency is 20 kHz,compared with the status of conventional continuous casting.

Self-assembly Behavior of Symmetrical Linear ABCA Tetrablock Copolymer:A Self-consistent Field Theory Study

ABCA tetrablock copolymers offer new opportunities for design of materials with novel structures. Using real-space self- consistent field theory and simulation, we systematically examined the self-assembly behavior of linear ABCA tetrablock copolymers in a 2D space. The simulation was carried out under conditions of symmetrical compositions and interactions. We focus on the influence of chain length ratio of block A and interactions between block A and other blocks B and C on the self-assembly behavior of the copolymer system. The simulation results show that most of the structures self-assembled by the ABCA tetrablock copolymers are centrosymmetric, such as diblock-like lameUa phase, two kinds of lameUae with beads at interface, two kinds of hierarchical lamella phase, hexagonal honeycomb-like phase, lamella phase with mixed BC and hexagonal spheres with mixed BC. Furthermore, we find that a novel noncentrosymmetric Janus spheres can be obtained when the interaction between blocks B and C is strong, whereas a noncentrosymmetric lamella phase was obtained at weak interaction between blocks B and C. Phase diagrams for the ABCA tetrablock copolymers with different interaction strength between blocks B and C are constructed by comparing free energies of candidate ordered structures. In addition, studies on the metastable behavior of the system reveal that enthalpy plays an important role in the metastable behavior of the ABCA tetrablock copolymer system. Our work can provide useful guide for structure control of such kind of tetrablock copolymers in experiments.

Characteristics of Nanosecond Pulsed Discharges in Atmospheric Helium Microplasmas

Microplasmas are very interesting due to their unique properties and achievable regimes maintained at atmospheric pressures. Due to the small scales, numerical modeling could contribute to the understanding of underlying phenomena as it provides access to local parameters--and complements experimental global characteristics. A self-consistent formalism, applied to nanosecond pulsed atmospheric non-equilibrium helium plasmas, reveals that several successive discharges can persist as a result of a combined volume and dielectric surface effects. The valuable insights provided by the spatiotemporal simulation results show the critical importance of coupled gas and plasma dynamics--namely gas heating and electric field reversals.

A numerical study on Rayleigh-Taylor instability of aluminum plates driven by detonation

The authors,using elastic-plastic hydrodynamic code,present the Rayleigh-Taylor (RT) instability of Al plates driven by high-explosive detonation. Our numerical study assumes the material is fluid,or it is an elastic-plastic solid,and we compare the results of these simulations with the experimental data. For the numerical simulation of Rayleigh-Taylor instability of the metal driven by high-explosive detonation,the elastic-plastic effect must be assumed. The result of the simulation is different from the experiment,using only equation of state. However,the growth of perturbation agrees well with the measured growth under the second assumption. There is a cutoff wavelength for RT instability of the metal. The growth of perturbation is stable for short wavelength. The growth increases rapidly as the wavelength increases.