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.

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.

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.

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.