Study on hot deformation behavior of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy using a combination of strain-compensated Arrhenius constitutive model and finite element simulation method

Isothermal hot compression experiments were conducted on homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy to investigate hot deformation behavior at the temperature range of 673-773 K and the strain rate range of 0.001-1 s^(-1)by using a Gleeble-1500D thermo mechanical simulator.Metallographic characterization on samples deformed to true strain of 0.70 illustrates the occurrence of flow localization and/or microcrack at deformation conditions of 673 K/0.01 s^(-1),673 K/1 s^(-1)and 698 K/1 s^(-1),indicating that these three deformation conditions should be excluded during hot working of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy.Based on the measured true stress-strain data,the strain-compensated Arrhenius constitutive model was constructed and then incorporated into UHARD subroutine of ABAQUS software to study hot deformation process of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy.By comparison with measured force-displacement curves,the predicted results can describe well the rheological behavior of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy,verifying the validity of finite element simulation of hot compression process with this complicated constitutive model.Numerical results demonstrate that the distribution of values of material parameters(α,n,Q and ln A)within deformed sample is inhomogeneous.This issue is directly correlated to the uneven distribution of equivalent plastic strain due to the friction effect.Moreover,at a given temperature the increase of strain rate would result in the decrease of equivalent plastic strain within the central region of deformed sample,which hinders the occurrence of dynamic recrystallization(DRX).

Finite element simulation of inertia friction welding of superalloy bars

A thermo-mechanical coupling.finite element model was built to investigate the inertia friction welding of GH4169 bars. The remeshing and map solution techniques were adopted. Ttle whole welding process was investigated by adopting an innovative heat generation model and the flywheel rotational speed measured via the experiment. The simulated evolution of axial shortening shows a good agreement with the experiment. In addition, extensive .strain concentration presents in the interface and flash, and the largest ,strain exists near the flash root. Moreover, an intere.sting thermal reflux phenomenon during the cooling stage was found.

RESEARCH ON THE SELECTION OF FRICTION MODELS IN THE FINITE ELEMENT SIMULATION OF WARM EXTRUSION

During the process of finite element simulation of precision warm forging, the selection of friction models has a direct effect on the precision accuracy of finite element simulation results. Among all the factors which influence the selection of friction models, the distribution rule of normal stress at the tool-workpiece interface is a key one. To find out the distribution rule of normal stress at the tool-workpiece interface, this paper has made a systematic research on three typical plastic deformation processes: forward extrusion, backward extrusion, and lateral extrusion by a method of finite element simulation. Then on the base of synthesizing and correcting traditional friction models, a new general friction model which is fit for warm extrusion is developed at last.

Finite element simulation on the deep drawing of titanium thin-walled surface part

The deep drawing of titanium thin-walled surface part was simulated based on a self-developed three-dimensional finite element model. After an investigation on forming rules, a virtual orthogonal experimental design was adopted to determine the significance of processing parameters, such as die radius, blank holder force, and friction coefficient, on the forming process. The distributions of thickness and equivalent plastic strain of the drawn part were evaluated. The results show that die radius has a relative major influence on the deep drawing process, followed by friction coefficient and blank holder force.

THREE-DIMENSIONAL FINITE ELEMENT SIMULATION OF TOTAL KNEE JOINT IN GAIT CYCLE

Based on CT scanning pictures from a volunteer＇s knee joint, a three-dimensional finite element model of the healthy human knee joint is constructed including complete femur, tibia, fibular, patellar and the main cartilage and ligaments. This model was validated using experimental and numerical results obtained from other authors. The pressure distribution of contact surfaces of knee joint are calculated and analyzed under the load action of ‘heel strike＇, ‘single limb stance＇ and ‘toe-off＇. The results of the gait cycle are that the contact areas of medial cartilage are larger than that of lateral cartilage; the contact force and contact areas would grow larger with the load increasing; the pressure of lateral meniscus is steady, relative to the significant variation of peak pressure in medial meniscus; and the peak value of contact pressure on all components are usually found at about 4570 of the gait cycle.

Discrete element simulation of crushable rockfill materials

A discrete element method was used to study the evolution of particle crushing in a rockfill sample subjected to triaxial shear. A simple procedure was developed to generate clusters with arbitrary shapes, which resembled real rockfill particles. A theoretical method was developed to define the failure criterion for an individual particle subjected to an arbitrary set of contact forces. Then, a series of numerical tests of large-scale drained triaxial tests were conducted to simulate the behaviors of the rockfill sample. Finally, we examined the development of micro-characteristics such as particle crushing, contact characteristics, porosity, deformation, movement, and energy dissipation. The simulation results were partially compared with the laboratory experiments, and good agreement was achieved, demonstrating that the particle crushing model proposed can be used to simulate the drained triaxial test ofrockfill materials. Based on a comparison of macro behaviors of the roekfill sample and micro structures of the particles, the microscopic mechanism of the rockfill materials subjected to triaxial shear was determined qualitatively. It is shown that the crushing rate, rather than the number of crushed particles, can be used to reflect the relationship between macro- and micro-mechanical characteristics of rockfill materials. These research results further develop our understanding of the deformation mechanism of rockfill materials.

Finite element simulation for mechanical response of surface mounted solder joints under different temperature cycling

Nonlinear finite element simulation for mechanical response of surface mounted solder joint under different temperature cycling was carried out. Seven sets of parameters were used in order to evaluate the influence of temperature cycling profile parameters. The results show that temperature cycling history has significant effect on the stress response of the solder joint. Based on the concept of relative damage stress proposed by the authors, it is found that enough high temperature holding time is necessary for designing the temperature cycling profile in accelerated thermal fatigue test.

Finite element simulation of welded thin-walled stainless steel container based on SYSWELD

The temperature field and stress fields of 18 - 8 stainless steel container structure were computed during and after tungsten inert gas （TIG） arc welding based on the SYSWELD software. The convection, radiation and conduction were all considered during the simulation process as well as temperature-dependent material properties. The results show that the peak temperature occurs on the heat source location. Steep temperature gradients are observed ahead of the heat source. Axial tensile stress and hoop compressive stress are observed in the weld seam between cylinder and head. Axial compressive stress and hoop tensile stress are observed near the weld seam between cylinder and heads. Axial compressive stress and hoop tensile stress are observed in the axial weld seam of cylinder. Axial tensile stress and hoop compressive stress are observed near the axial weld seam of cylinder. The aim of the above research is to provide a basic theory and some calculation methods for the thin-walled container welding technology so that the failures of these structures in service due to residual stresses may be minimized.

Finite Element Simulation of In-Stent Restenosis with Tissue Growth Model

In this study, a finite element simulation of in-stent restenosis (ISR) is conducted to simulate the deployment and expansion of a stent in an occluded artery with a contact model and a mechanics-based growth model. A tissue growth model based on the multiplicative decomposition of deformation is applied to investigate the growth of the plaque and artery wall upon the stent’s implantation. Due to the high stresses at the contact points between the stent struts and the tissue, further tissue injury or restenosis is observed. The simulation results show that after the stent deployment, the von Mises stress is significantly larger in the plaque compared to the artery wall, especially in the region that is in contact with the stent. However, the growth of the plaque and artery tends to even out the stress concentration over time. The tissue growth is found to be more significant near the inner wall than the outer layer. A 0.77 mm restenosis is predicted, which agrees with published clinical observations. The features of the artery growth are carefully analyzed, and the underlying mechanism is discussed. This study is the first attempt to apply finite element analysis to artery restenosis, which establishes a framework for predicting ISR’s occurrence and severity. The results also provide insights into understanding the underlying mechanism of in-stent restenosis.

Contact parameter analysis and calibration in discrete element simulation of rice straw

Discrete element method was used to study and analyze the interaction between rice straws and between rice straw and agricultural machinery parts,thereby providing a scientific basis for post-harvest paddy field processing.Calibrations of rice straw-rice straw,rice straw-agricultural machinery part contact parameters(collision recovery coefficient,static friction coefficient and rolling friction coefficient)constitute an important prerequisite for the discrete element research process.In this study,the collision recovery coefficients of rice straw-steel and rice straw-rice straw were 0.230 and 0.357,respectively,which were calibrated by the collision method.The static friction coefficient and rolling friction coefficient of rice straw-steel were 0.363 and 0.208 respectively,which were calibrated by the inclined plate method and the slope method.The static friction coefficient and rolling friction coefficient of rice straw-rice straw were 0.44 and 0.07,respectively,which were calibrated by the split cylinder method.The paired t-test showed insignificant differences between calibration parameter simulation results and the physical test values(p>0.05).Taking the angle of repose that reflecting rice straw flow and friction characteristics as the evaluation index,the verification tests of the above calibration values indicated that the simulated angle of repose has no significant difference from the physical test value(p>0.05).The side plate lifting test on rice straw of different lengths showed no significant difference between the simulated angle of repose and the physical test value(p>0.05).This study can provide a basis for contact parameters choice in discrete element simulation analysis with rice straw-rice straw and rice straw-agricultural machinery parts as the research object.The calibration method can provide a reference for the contact parameter calibration of other crop straws.

Hot deformation behavior and finite element simulation of Mg-8.3Gd-4.4Y-1.5Zn-0.8Mn alloy

To study the hot deformation behavior of Mg-8.3 Gd-4.4 Y-1.5 Zn-0.8 Mn(wt%) alloy,hot compression tests were conducted using a Gleeble-3500 thermal simulator at temperatures ranging from 653 to773 K,true strain rates of 0.001-1 s^(-1),and a deformation degree of 60%.Results of hot compression experiments show that the flow stress of the alloy increases with the strain rate.The true stress-true strain curves are corrected by correcting the effect of temperature rise in the deformation process.Activation energy,Q,equal to 287380 J/mol and material constant,n,equal to 4.59 were calculated by fitting the true stress-true strain curves.Then,the constitutive equation was established and verified via finite element simulation.Results of the hot processing map show that the probability of material instability increases with the degree of deformation,which indicates that the material is not suitable for large deformation in a single pass.On the whole,the alloy is appropriate for multipass processing with small deformation and a suitable processing temperature and strain rate are 733 K and 0.01 s-1,respectively.

Effect of stress profile on microstructure evolution of cold-drawn commercially pure aluminum wire analyzed by finite element simulation

The evolution of microstructure in the drawing process of commercially pure aluminum wire （CPAW） does not only depend on the nature of materials, but also on the stress profile. In this study, the effect of stress profile on the texture evolution of the CPAW was systematically investigated by combining the numerical simulation and the microstructure observation. The results show that the tensile stress at the wire center promotes the formation of 〈111〉 texture, whereas the shear stress nearby the rim makes little contribution to the texture formation. Therefore, the 〈111 〉 texture at the wire center is stronger than that in the surface layer, which also results in a higher microhardness at the center of the CPAW under axial loading.2017 Published by Elsevier Ltd on behalf of The editorial office of Journal of Materials Science ＆ Technology.

FINITE ELEMENT MODEL AND SIMULATION OF ROTARY FORGING OF A DISC

The rotary forging process of a disc is simulated by 3-D finite element method.The motion of the rotary the is described as the combination of a revolution round the machine axis and a spin round the rotary die axis. Therefore, the workpiece can be loaded and unloaded partly and cyclically by the cone surface of the rotary the continuously, according with the practical rotary forging process. From the siumulation rasults, the causes of center-thinning during rotary forging of discs are that the locally loading of rotary die made the workpiece center get high radial and tangential tensile stresses, and then the shortening in axial direction and the elongating in tangential and radial direction occur continuous- ly.

Deformation warning index for reinforced concrete dam based on structural health monitoring data and numerical simulation

The material mechanical parameters of the dam body and foundation will change when a dam is reinforced during the aging process.This causes significant changes in the structural state of the project and makes it difficult to ensure its structural safety.In this study,a new deformation warning index for reinforced concrete dams was developed according to the prototype monitoring data,statistical models,three-dimensional finite element model(FEM)numerical simulation,and the critical conditions of the dam structure.A statistical model was established to separate the water pressure component.Then,a three-dimensional FEM of the reinforced concrete dam was constructed to simulate the water pressure component.Furthermore,the deformation components that affected the mechanical parameters of the dam under the same amount of reservoir water level change were separated and quantified accurately.In addition,the method for inversion of comprehensive mechanical parameters after dam reinforcement was used.The influence mechanisms of the deformation behavior of concrete dams under the reservoir water level and temperature changes were investigated.A new deformation warning index was developed by combining the forward-simulated critical water pressure component and temperature component in the period of extreme temperature decrease with the aging component separated by the statistical model.The new deformation warning index considers the structural state of the dam before and after reinforcement and links the structural strength criterion and the deformation evolution mechanisms.It provides a theoretical foundation and decision support for long-term service and operation management of reinforced dams.

Numerical simulation of the mechanical behavior of superconducting tape in conductor on round core cable using the cohesive zone model

Cables composed of rare-earth barium copper oxide(REBCO)tapes have been extensively used in various superconducting devices.In recent years,conductor on round core(CORC)cable has drawn the attention of researchers with its outstanding current-carrying capacity and mechanical properties.The REBCO tapes are wound spirally on the surface of CORC cable.Under extreme loadings,the REBCO tapes with layered composite structures are vulnerable,which can lead to degradation of critical current and even quenching of superconducting devices.In this paper,we simulate the deformation of CORC cable under external loads,and analyze the damage inside the tape with the cohesive zone model(CZM).Firstly,the fabrication and cabling of CORC are simulated,and the stresses and strains generated in the tape are extracted as the initial condition of the next step.Then,the tension and bending loads are applied to CORC cable,and the damage distribution inside the tape is presented.In addition,the effects of some parameters on the damage are discussed during the bending simulations.

Simulation research on collisions between highway corrugated beam guardrails and vehicles based on LS-DYNA

To explore the safety of highway traffic operations,the vehicle state and guardrail deformation during highway guardrail collisions are simulated and analyzed.The vehicle-guardrail collision is simulated by finite element software such as LS-DYNA and HyperMesh.The vehicle speed settings are 60,80,100 and 120 km/h,and the collision angles are 5°,10°,15°and 20°.The guardrail deformation,vehicle acceleration and energy changes under different collision speeds and angles are studied.The research results show that at the same collision speed,an increase in the collision angle causes more serious damage to the vehicle,a greater transverse displacement of the guardrail,and a greater range of car acceleration fluctuations.When the collision angle is the same,an increase in the collision speed causes greater lateral displacement of the guardrail,a greater vehicle acceleration fluctuation range,and more serious vehicle damage.The results of the study can provide a reference for demonstrating highway guardrail safety.

Finite Element Simulation of Rod and Wire Continuous Rolling

This paper discusses the application of several techniques involved in the development of the 3D finite element (FE) models of rod and wire continuous rolling process.The FE models are implemented into the FE-program MSC.Marc and used to investigate the thermal and mechanical behavior of billet during the rolling process.All nonlinear equations included in the models are solved by the static and dynamic procedures,respectively.Data transfer technique is proposed to keep the continuity of simulation results.And the computational time of static procedure is significantly reduced by using a rigid pushing body.In all models,the constant time step method and the auto time step method are respectively used to define time step for the solution of equations.Simulation results of the models with different time step methods are compared.And comparison between calculated values and measured ones of the temperature at the surface of billet shows the validity of the FE models.

DEFORMATION ANALYSIS OF SHEET METAL SINGLE-POINT INCREMENTAL FORMING BY FINITE ELEMENT METHOD SIMULATION

Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.

Numerical simulation of hydraulic fracturing and associated microseismicity using finite-discrete element method

Hydraulic fracturing （HF） technique has been extensively used for the exploitation of unconventional oiland gas reservoirs. HF enhances the connectivity of less permeable oil and gas-bearing rock formationsby fluid injection, which creates an interconnected fracture network and increases the hydrocarbonproduction. Meanwhile, microseismic （MS） monitoring is one of the most effective approaches to evaluatesuch stimulation process. In this paper, the combined finite-discrete element method （FDEM） isadopted to numerically simulate HF and associated MS. Several post-processing tools, includingfrequency-magnitude distribution （b-value）, fractal dimension （D-value）, and seismic events clustering,are utilized to interpret numerical results. A non-parametric clustering algorithm designed specificallyfor FDEM is used to reduce the mesh dependency and extract more realistic seismic information.Simulation results indicated that at the local scale, the HF process tends to propagate following the rockmass discontinuities; while at the reservoir scale, it tends to develop in the direction parallel to themaximum in-situ stress. 2014 Institute of Rock and Soil Mechanics, Chinese Academy of Sciences. Production and hosting byElsevier B.V. All rights reserved.

Safety Length Simulation of Natural Gas Pipeline Subjected to Transverse Landslide

The safety of natural gas pipeline is often severely threatened by the transverse landslide. At home and abroad, it is the first time to study the safe length of the pipeline when affected by landslide, and take the safe length of the pipeline as an engineering practical index. Therefore, it is of great significance to study the influence of transverse landslide affecting the safety of natural gas pipeline when a certain length of pipeline is thrusted, and to establish practical index and simulation method for prediction and prevention of the landslide hazards to gas pipeline. Based on the current research results, this study could be divided into three steps: First of all, with the help of ANSYS finite element software, the model of transverse landslide acting on the gas pipeline can be set up, then the length value of gas pipeline safely withstanding transverse landslide can be calculated;Secondly, using the strength reduction method, which is commonly used in the research of landslide stability, can establish three-dimensional model of the landslide and pipes in the ABAQUS finite element software, next, under the same landslide pushed length, the calculation results will be obtained;Finally, to draw reliable conclusions, all calculated results of the former two methods will be linked to synthetically and comparatively analyze, then the length value of common X80 gas pipeline safely bearing transverse landslide can be got. All results can provide some references for engineering and design.