Grain statistics effect on deformation behavior in asymmetric rolling of pure copper foil by crystal plasticity finite element model

The grain statistics effect was investigated through asymmetric rolling of pure copper foil by a realistic polycrystalline aggregates model and crystal plasticity element finite model.A polycrystalline aggregate model was generated and a crystal plasticity-based finite element model was developed for each grain and the specimen as a whole.The crystal plasticity model itself is rate dependent and accounts for local dissipative hardening effects and the original orientation of each grain was generated based on the orientation distribution function（ODF）.The deformation behaviors,including inhomogeneous material flow,decrease of contact press and roll force with the increase of grain size for the constant size of specimens,were studied.It is revealed that when the specimens are composed of only a few grains across thickness,the grains with different sizes,shapes and orientations are unevenly distributed in the specimen and each grain plays a significant role in micro-scale plastic deformation and leads to inhomogeneous deformation and the scatter of experimental and simulation results.The slip system activity was examined and the predicted results are consistent with the surface layer model.The slip band is strictly influenced by the misorientation of neighbor grain with consideration of slip system activity.Furthermore,it is found that the decrease of roll force and the most active of slip system in surface grains are caused by the increase of free surface grain effect when the grain size is increased.The results of the physical experiment and simulation provide a basic understanding of micro-scaled plastic deformation behavior in asymmetric foil rolling.

Equal channel angular extrusion of NiTi shape memory alloy tube

As a new attempt, equal channel angular extrusion （ECAE） of nickel-titanium shape memory alloy （NiTi SMA） tube was investigated by means of process experiment, finite element method （FEM） and microscopy. NiTi SMA tube with the steel core in it was inserted into the steel can during ECAE of NiTi SMA tube. Based on rigid-viscoplastic FEM, multiple coupled boundary conditions and multiple constitutive models were used for finite element simulation of ECAE of NiTi SMA tube, where the effective stress field, the effective strain field and the velocity field were obtained. Finite element simulation results are in good accordance with the experimental ones. Finite element simulation results reveal that the velocity field shows the minimum value in the corner of NiTi SMA tube, where severe shear deformation occurs. Microstructural observation results reveal that severe plastic deformation leads to a certain grain orientation as well as occurrence of substructures in the grain interior and dynamic recovery occurs during ECAE of NiTi SMA tube. ECAE of NiTi SMA tube provides a new approach to manufacturing ultrafine-grained NiTi SMA tube.

Prediction of grain scale plasticity of NiTi shape memory alloy based on crystal plasticity finite element method

Grain scale plasticity of NiTi shape memory alloy(SMA)during uniaxial compression deformation at 400℃was investigated through two-dimensional crystal plasticity finite element simulation and corresponding analysis based on the obtained orientation data.Stress and strain distributions of the deformed NiTi SMA samples confirm that there exhibits a heterogeneous plastic deformation at grain scale.Statistically stored dislocation(SSD)density and geometrically necessary dislocation(GND)density were further used in order to illuminate the microstructure evolution during uniaxial compression.SSD is responsible for sustaining plastic deformation and it increases along with the increase of plastic strain.GND plays an important role in accommodating compatible deformation between individual grains and thus it is correlated with the misorientation between neighboring grains,namely,a high GND density corresponds to large misorientation between grains and a low GND density corresponds to small misorientation between grains.

Numerical Analysis of Finite Deformation of Overbroken Rock Mass in Gob Area Based on Euler Model of Control Volume

The overbroken rock mass of gob areas is made up of broken and accumulated rock blocks compressed to some extent by the overlying strata. The beating pressure of the gob can directly affect the safety of mining fields, formarion of road retained along the next goaf and seepage of water and methane through the gob. In this paper, the software RFPA＇2000 is used to construct numerical models. Especially the Euler method of control volume is proposed to solve the simulation difficulty arising from plastically finite deformations. The results show that three characteristic regions occurred in the gob area： （1） a naturally accumulated region, 0-10 m away from unbroken surrounding rock walls, where the beating pressure is nearly zero; （2） an overcompacted region, 10-20 m away from unbroken walls, where the beating pressure results in the maximum value of the gob area; （3） a stable compaction region, more than 20 m away from unbroken walls and occupying absolutely most of the gob area, where the beating pressures show basically no differences. Such a characteristic can exolain the easy-seeoaged “O”-ring phenomena around mining fields very well.

Deformation behaviors of 21-6-9 stainless steel tube numerical control bending under different friction conditions

For contact dominated numerical control(NC) bending process of tube, the effect of friction on bending deformation behaviors should be focused on to achieve precision bending forming. A three dimensional(3D) elastic-plastic finite element(FE) model of NC bending process was established under ABAQUS/Explicit platform, and its reliability was validated by the experiment. Then, numerical study on bending deformation behaviors under different frictions between tube and various dies was explored from multiple aspects such as wrinkling, wall thickness change and cross section deformation. The results show that the large friction of wiper die-tube reduces the wrinkling wave ratio η and cross section deformation degree ΔD and increases the wall thinning degree Δt. The large friction of mandrel-tube causes large η, Δt and ΔD, and the onset of wrinkling near clamp die. The large friction of pressure die-tube reduces Δt and ΔD, and the friction on this interface has little effect on η. The large friction of bending die-tube reduces η and ΔD, and the friction on this interface has little effect on Δt. The reasonable friction coefficients on wiper die-tube, mandrel-tube, pressure die-tube and bending die-tube of 21-6-9(0Cr21Ni6Mn9N) stainless steel tube in NC bending are 0.05-0.15, 0.05-0.15, 0.25-0.35 and 0.25-0.35, respectively. The results can provide a guideline for applying the friction conditions to establish the robust bending environment for stable and precise bending deformation of tube bending.

Simple shear endochronic equations for finite plastic deformation

The endochronic equations proposed by Valanis (1980) were extended to a finite deformation range. Jaumanns rate, Fus rate and Wus rate were incorporated into the endochronic equations to analyze simple shear finite deformation. Incremental equations and numerical solutions are deduced for three endochronic objective models. The results show that an oscillatory shear stress response to a monotonically increasing shear strain occurs when the Jaumanns rate objective model is employed for endochronic materials. The oscillatory response is dependent on the adopted objective rate. Compared with the Jaumanns rate, the Fus rate and the Wus rate satisfy the restrictions to elastic-plastic constitutive relations and are in agreement with the experimental results.

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.

Structural Optimization of Lap Link Based on Elastoplastic Finite Element Analysis

Based on finite-deformation elastoplastic theory, a scheme to solve the structural problems of the lap link by using ANSYS is proposed. The analysis results show that the maximum deformation exists at the loading spot of the lateral pin and the stiffness of this area needs to be enhanced; the maximum stresses occur at the two sides adjacent to the loading spot and the intensity around this region should be strengthened;the materials at the pole and pinhole with relatively low stress are redundant and removing excessive weight is possible. Based on the analysis, corresponding improvements are tentatively made, and the simulation results prove that, the stiffness and intensity of the new structure are improved. Furthermore, the reliability and validity of this design are verified by tensile tests of two types of structure.