Three-dimensional Finite Element modelling of laser shock peening process

Laser shock peening (LSP) is an innovative surface treatment technique for metal alloys, with the great improvement of their fatigue, corrosion and wear resistance performance. Finite element method has been widely applied to simulate the LSP to provide the theoretically predictive assessment and optimally parametric design. In the current work, 3-D numerical modelling approaches, combining the explicit dynamic analysis, static equilibrium analysis algorithms and different plasticity models for the high strain rate exceeding 106s-1, are further developed. To verify the proposed methods, 3-D static and dynamic FEA of AA7075-T7351 rods subject to two-sided laser shock peening are performed using the FEA package–ABAQUS. The dynamic and residual stress fields, shock wave propagation and surface deformation of the treated metal from different material modelling approaches have a good agreement.

Colloidal interaction between a rigid solid and a fluid drop

We present results of a theoretical study of the effect of surface deformation on a macroscopic system composed of a solid surface interacting with a fluid drop through electrostatic double-layer forces. The analysis involves numerically solving a Laplace equation suitably modified to describe the shape of a liquid drop subjected to a repulsive double-layer force. The latter is evaluated in nonlinear mean-field theory. Some analytical results are also given. The results indicate that although deformation need not be significant on the macroscopic scale, its effect on the interaction is significant and modifies the picture usually presented in DLVO theory. The decay length of the exponential repulsion deviates marginally from the Debye length, dependent on the interfacial tension of the drop. More significantly, at separations where the double-layer force becomes comparable to the internal pressure of the drop, the net force between the two bodies, the local radius of curvature of the drop, and the amount of deformation grow abruptly. The results of this work are relevant to emulsion stability, micelle, vesicle, and cell interactions, and recent experiments on bubble-particle interaction.

The 'wimple' : rippled deformation of a fluid drop caused by hydrodynamic and surface forces during thin film drainage

It is well-known that hydrodynamic pressures in a thin draining liquid film can cause inversion of the curvature of a drop or bubble surface as it approaches another surface, creating a so-called “dimple”. Here it is shown that a more complicated rippled shape, dubbed a “wimple”, can be formed if a fluid drop that is already close to a solid wall is abruptly pushed further toward it. The wimple includes a central region in which the film remains thin, surrounded by a ring of greater film thickness that is bounded at the outer edge by a barrier rim where the film is thin. This shape later evolves into a conventional dimple bounded by the barrier rim, which then drains in the normal way. During the evolution from wimple to dimple, some of the fluid in the thicker part of the film ring flows toward the central region before eventually draining in the opposite direction. Although the drop is pressed toward the wall, the central part of the drop moves away from the wall before approaching it again. This is observed even when the inward push is too small to create a wimple.

Effect of membrane stress on surface roughness changes in sheet forming

Friction plays an important role in sheet metal forming (SMF) and the roughness of the surface of the sheet is a major factor that influences friction. In finite element method (FEM) models of metal forming, the roughness has usually been assumed to be constant; even though it is commonly observed that sheet drawn under tension over a tool radius results in the surface becoming shiny, indicating a major change in surface morphology. An elastic–plastic FEM model for micro-contact between a flat surface and a single roughness peak has been developed. The model was used to investigate the effect of the membrane stress in the sheet on the deformation of an artificial roughness peak. From the simulation results, the change in asperity, or deformation of the local peak, for a given nominal tool contact stress is significantly influenced by the local substrate stress. The height of the asperity decreases with increasing substrate stress and the local pressure is much higher than the nominal pressure. In addition, the local contact stress decreases with an increase in the substrate stress levels.

Nucleation sites for ultrafine ferrite produced by deformation of austenite during single-pass strip rolling

An austenitic Ni-30 wt pct Fe alloy, with a stacking-fault energy and deformation characteristics similar to those of austenitic low-carbon steel at elevated temperatures, has been used to examine the defect substructure within austenite deformed by single-pass strip rolling and to identify those features most likely to provide sites for intragranular nucleation of ultrafine ferrite in steels. Samples of this alloy and a 0.095 wt pct C-1.58Mn-0.22Si-0.27Mo steel have been hot rolled and cooled under similar conditions, and the resulting microstructures were compared using transmission electron microscopy (TEM), electron diffraction, and X-ray diffraction. Following a single rolling pass of ∼40 pct reduction of a 2mm strip at 800 °C, three microstructural zones were identified throughout its thickness. The surface zone (of 0.1 to 0.4 mm in depth) within the steel comprised a uniform microstructure of ultrafine ferrite, while the equivalent zone of a Ni-30Fe alloy contained a network of dislocation cells, with an average diameter of 0.5 to 1.0 µm. The scale and distribution and, thus, nucleation density of the ferrite grains formed in the steel were consistent with the formation of individual ferrite nuclei on cell boundaries within the austenite. In the transition zone, 0.3 to 0.5 mm below the surface of the steel strip, discrete polygonal ferrite grains were observed to form in parallel, and closely spaced “rafts” traversing individual grains of austenite. Based on observations of the equivalent zone of the rolled Ni-30Fe alloy, the ferrite distribution could be correlated with planar defects in the form of intragranular microshear bands formed within the deformed austenite during rolling. Within the central zone of the steel strip, a bainitic microstructure, typical of that observed after conventional hot rolling of this steel, was observed following air cooling. In this region of the rolled Ni-30Fe alloy, a network of microbands was observed, typical of material deformed under plane-strain conditions.

Finite element simulation of deformation processes of micro-components

The aim of this paper is to improve the understanding of deformation of micro medical needle and thread during assembly and then to develop an economical and flexible deformation method. Therefore, the swaging process is computationally simulated with the finite element method in this paper. A commercially available explicit nonlinear finite element analysis code, LS-Dyna, is used to model the 3-D deformation and contact problem. As the firmness of the assembly on the needle depends on the contact force and friction, the contact and the slide between the needle and thread are taken into account in the simulation. The general surface-to-surface contact algorithm (STS) is used to simulate the contact. The paper provides an insight into the deformation of the micro products.

Hippocampal deformation mapping in MRI-negative PET-positive temporal lobe epilepsy

Objectives: To compare hippocampal surface structure, using large deformation high dimensional mapping (HDM-LD), in subjects with temporal lobe epilepsy (TLE) with (HS+ve) and without (HS−ve) hippocampal sclerosis.

Methods: The study included 30 HS−ve subjects matched with 30 HS+ve subjects from the previously reported epilepsy patient cohort. To control for normal right–left asymmetries of hippocampal surface structure, subjects were regrouped based on laterality of onset of epileptic seizures and presence of HS. Gender ratio, age, duration of epilepsy and seizure frequency were calculated for each of the four groups. Final HDM-LD surface maps of the right and left TLE groups were compared to define differences in subregional hippocampal involvement within the groups.

Results: There were no significant differences in comparisons of the left TLE (left HS−ve compared with HS+ve) or right TLE (right HS−ve compared with HS+ve) groups with respect to age, duration of epilepsy or seizure severity scores. HDM-LD maps showed accentuated surface changes over the lateral hippocampal surface, in the region of the Sommer sector, in the hippocampi affected by HS. However, HS−ve hippocampi showed maximal surface changes in a different pattern, and did not involve the region of Sommer sector.

Conclusion: We conclude that differences in segmental volume loss between the HS−ve and HS+ve groups are suggestive that the underlying pathophysiology of hippocampal changes in the two groups is different, and not related to chronic seizure duration or severity.

Characteristics of the contraction twins formed close to the fracture surface in Mg-3A1-1Zn alloy deformed in tension

Characteristics of the “contraction” twins, formed close to the fracture surface in Mg–3Al–1Zn alloy deformed in tension approximately perpendicular to the grain c-axes, are investigated using transmission electron microscopy. The grain c-axis contractions were largely accommodated by {1011}-{1012} source double-twins in a variant characterized by 38° ⟨1210⟩ source twin/matrix misorientation in conjunction with dislocation slip. A possible interpretation of the observed preference for this variant formation is given and some crystal plasticity modelling is performed to elucidate the matter.

Deformation modes and anisotropy in magnesium alloy AZ31

A strongly textured sheet of magnesium alloy AZ31 has been subjected to tensile testing at temperatures between ambient and 300°C. Structures have been examined by optical and transmission electron microscopy and also by atomic force microscopy to quantify surface displacements seen at grain boundaries. Plastic anisotropy varies strongly with test temperature as was observed previously by Agnew and Duygulu. The present findings do not support the view that crystallographic <c + a> becomes a major contributor to deformation at higher temperatures. Rather, the material behaviour reflects an increasing contribution from grain boundary sliding despite the relatively high strain rate (I 0^-3 s^-1) used in the mechanical tests.

Effects of deformation-induced heating on bond strength of rolled metal multilayer

The bond strength of various metal multilayers produced by cold rolling of metal foils with different thermal conductivity was investigated. Results indicated that under the same conditions of deformation and surface preparation, the metallic multilayer system with low thermal conductivity exhibited relative high bond strength while high thermal conductivity metal system may fail to be roll-bonded together. The relationship between the deformation-induced localized heating and the bond strength were discussed. The deformation-induced localized heating in the low thermal conductivity metal multilayer systems may provide opportunities for achieving a successful accumulative roll bonding or a “cold roll/heat treatment/cold roll” process to synthesize metallic multilayer materials.

Deformation and frictional heating in relation to wear in sheet metal stamping

In the automotive industry, press production rates often need to be reduced in order to minimize tool wear issues and successfully stamp advanced high strength steels. This indicates that heating affects may be important. This paper examines friction and deformational heating at the die radius during sheet metal stamping, using finite element analysis. The results show that high temperatures, of up to 130°C, can occur at the die radius surface. Such behavior has not been previously reported in the literature, for what is expected to be ‘cold’ sheet metal stamping conditions. It will be shown that the temperature rise is due to the increased contact stresses and increased plastic work, associated with stamping AHSS. Consequently, new insights into the local contact conditions in sheet metal stamping were obtained. The outcomes of this work may impact the wear models and tests employed for future tool wear analyses in sheet metal stamping.

The effect of surface and hydrodynamic forces on the shape of a fluid drop approaching a solid surface

This paper describes an experiment designed to measure surface and hydrodynamic forces between a mercury drop and a flat mica surface immersed in an aqueous medium. An optical interference technique allows measurement of the shape of the mercury drop as well as its distance from the mica, for various conditions of applied potential, applied pressure, and solution conditions. This enables a detailed exploration of the surface forces, particularly double-layer forces, between mercury and mica. A theoretical analysis of drop shape under the influence of surface forces shows that deformation of the drop is a sensitive indicator of the forces, as well as being a very important factor in establishing the overall interaction between the solid and the fluid.

Measurement of the deformation and adhesion of solids in contact

Two curved surfaces of molecularly smooth mica are brought into contact under a controlled load, and their deformed shape is measured using optical interference fringes of equal chromatic order. This technique allows exceptionally accurate measurements of surface profiles at separations down to a molecular scale. Contact between the surfaces can be made either adhesive or nonadhesive by suitable choice of the medium between them. Results have been obtained in both cases and compared with the theories of Hertz (nonadhesive contact) and Johnson, Kendall, and Roberts (adhesive contact).

Tribological behaviour of pure Ti with a nanocrystalline surface layer under different loads

Surface mechanical attrition treatment (SMAT), a novel surface severe plastic deformation method, was carried out for titanium (Ti) to create a gradient-structured Ti (SMAT Ti). The tribological behaviour was studied under different loads and dry sliding conditions. The results showed that the deformation layer of SMAT Ti was about 160 μm. The friction and wear results showed that the wear resistance of SMAT Ti was enhanced compared to the coarse-grained (CG) counterpart. SMAT Ti showed abrasive wear under 1 and 5 N, and exhibited abrasive and adhesive wear under 2 N. While CG Ti showed abrasive and adhesive wear under 1-2 N, and exhibited abrasive wear under 5 N for the work hardening effects.