Numerical simulations of crack tip fields in polycrystalline plastic solids

In this paper, modes I and II crack tip fields in polycrystalline plastic solids are studied under plane strain, small scale yielding conditions. Two different initial textures of an Al–Mg alloy, viz., continuous cast AA5754 sheets in the recrystallized and cold rolled conditions, are considered. The former is nearly-isotropic, while the latter displays distinct anisotropy. Finite element simulations are performed by employing crystal plasticity constitutive equations along with a Taylor-type homogenization as well as by using the Hill quadratic yield theory. It is found that significant texture evolution occurs close to the notch tip which profoundly influences the stress and plastic strain distributions. Also, the cold rolling texture gives rise to higher magnitude of plastic strain near the tip.

Numerical simulations of crack tip fields in polycrystalline plastic solids

In this paper, modes I and II crack tip fields in polycrystalline plastic solids are studied under plane strain, small scale yielding conditions. Two different initial textures of an Al-Mg alloy, viz.,continuous cast AA5754 sheets in the recrystallized and cold rolled conditions, are considered. The former is nearly-isotropic, while the latter displays distinct anisotropy. Finite element simulations are performed by employing crystal plasticity constitutive equations along with a Taylor-type homogenization as well as by using the Hill quadratic yield theory. It is found that significant texture evolution occurs close to the notch tip which profoundly influences the stress and plastic strain distributions. Also, the cold rolling texture gives rise to higher magnitude of plastic strain near the tip. (C) 2010 Elsevier Ltd. All rights reserved.

Evolution of Transformation Texture in a Metastable B - Titanium Alloy

Texture evolution in h. c. p. (alpha) phase derived from aging of a differently processed metastable b.c.c. (beta) titanium alloy was investigated. The study was aimed at examining (i) the effect of different b. c. c. cold rolling textures and (ii) the effect of different defect structures on the h. c. p transformation texture. The alloy metastable beta alloy Ti-10V-4.5Fe-1.5Al was rolled at room temperature by unidirectional (UDR) and multi-step cross rolling (MSCR). A piece of the as-rolled materials were subjected to aging in order to derive the h. c. p. (alpha) phase. In the other route, the as-rolled materials were recrystallized and then aged. Textures were measured using X-ray as well as Electron Back Scatter Diffraction. Rolling texture of beta phase, as characterized by the presence of a strong gamma fibre, was found stronger in M S C R compared to UDR, although they were qualitatively similar. The stronger texture of MSCR sample could be attributed to the inhomogeneous deformation taking place in the sample that might contribute to weakening of texture. Upon recrystallization in beta phase field close to beta-transus. the textures qualitatively resembled the corresponding beta deformation textures; however, they got strengthed. The aging of differently beta rolled samples resulted in the product alpha-phase with different textures. The (UDR + Aged) sample had a stronger texture than (MSCR + Aged) sample, which could be due to continuation of defect accumulation in UDR sample, thus providing more potential sites for the nucleation of alpha phase. The trend was reversed in samples recrystallized prior to aging. The (MSCR + Recrystallized + Aged) sample showed stronger texture of alpha phase than the (UDR + Recrystallized + Aged) sample. This could be attributed to extensive defect annihilation in the UDR sample on recrystallization prior to aging. The (MSCR + Aged) sample exhibited more alpha variants when compared to (MSCR + Recrystallized + Aged) sample. This has been attributed to the availability of more potential sites for nucleation of alpha phase in the former. It could be concluded that alpha transformation texture depends mainly on the defect structure of the parent phase.

Evolution of Texture and Microstructure in Deformed and Annealed Copper-Iron Multilayer

The effect of multiple phases on the evolution of texture during cold rolling and annealing of a copper-iron multilayer, fabricated by accumulative roll bonding, has been studied. The presence of an iron layer affects the deformation texture of the copper layer only at very large strains. On the other hand, a strong effect of copper on iron is observed at both small and large strains. At smaller strains, the larger deformation carried by the copper suppresses the texture development in the iron, whereas, at higher strains, selection of specific orientation relationship at the interface influences the texture of the iron layer. Shear banding and continuous dynamic recrystallization were found to influence the evolution of texture in the copper layer. The influence of large plastic deformation on the recrystallization behavior of copper is demonstrated with the suppression of typical fcc annealing texture components, described as constrained recrystallization. Evolution of typical annealing texture component is suppressed because of the multilayer microstructure. The plane of the interface formed during deformation is determined by a combination of the rolling texture of individual phases, constrained annealing, and the tendency to form a low-energy interface between the two phases during annealing.

Fine scale structures from deformation of aluminium containing small alumina particles

Microstructures and mechanical properties have been studied in aluminium containing a fine dispersion of alumina particles, deformed by cold-rolling to strains between 1.4 and 3.5. The microstructure was characterised by TEM. The deformation structures evolved very rapidly, forming a nanostructured material, with fine subgrains about 0.2 μm in diameter and a fraction of high-angle boundaries which was already high at a strain of 1.4, but continued to increase with rolling strain. The yield stress and ductility of the rolled materials were measured in tension, and properties were similar for all materials. Yield stress measurements were correlated with estimates made using microstructural models. The role of small particles in forming and stabilising the deformation structure is discussed. This nanostructured cold-deformed alloy has mechanical properties which are usefully enhanced at comparatively low cost. This gives it, and similar particle-strengthened alloys, good potential for commercial exploitation. © 2002 Acta Materialia Inc. Published by Elsevier Science Ltd. All rights reserved.

Plastic Deformation Of Nanocrystalline Nickel

A high-resolution electron microscopy study has uncovered the plastic behavior of accommodating large strains in nanocrystalline (NC) Ni subject to cold rolling at liquid nitrogen temperature. The activation of grain-boundary-mediated-plasticity is evidenced in NC-Ni, including twinning and formation of stacking fault via partial dislocation slips from the grain boundary. The formation and storage of 60A degrees full dislocations are observed inside NC-grains. The grain/twin boundaries act as the barriers of dislocation slips, leading to dislocation pile-up, severe lattice distortion, and formation of sub-grain boundary. The vicinity of grain/twin boundary is where defects preferentially accumulate and likely the favorable place for onset of plastic deformation. The present results indicate the heterogeneous and multiple natures of accommodating plastic strains in NC-grains.

冷轧生产线机组作业计划过程中的投料混合比算法

为了实现冷轧生产线的均衡生产,提出了机组排产作业计划过程中的投料混合比算法。在该算法中,首先根据各道工序机组的生产能力、产品类型、故障和生产过程中的随机干扰等,计算在生产计划期内依概率平均的最佳缓冲区库存量,该库存量能够使机组实现均衡生产;其次,在现有在制库存条件下,考虑生产机组的生产能力和生产的产品类型,提出了本工序机组负荷平衡的机组排产作业计划在线生成方法;最后,结合上述两种方法,利用程序迭代搜索方式求解,既保证本道工序机组负荷平衡,也保证下道工序最佳库存的优化投料混合比,保证了冷轧生产线均衡生产的可行性。

冷轧MES机组作业计划过程中的任务分配法

基于鞍钢新轧集团股份有限公司冷轧薄板厂MES工程的实际情况,介绍了机组排产作业计划过程中的任务分配方法。该方法以机组与生产任务的最佳匹配、机组的负荷平衡为性能指标,采用了实时最小负荷分配规则,科学地解决了冷轧生产线CIMS环境下机组排产作业计划的在线生成问题,实现了生产线上的生产路径优化控制,从而提高了生产质量和设备利用率。

鞍钢冷轧厂制造执行系统研究

鞍钢新轧钢股份有限公司冷轧厂制造执行系统(MES)覆盖了从接收用户合同到产品发货的整个生产经营活动。接收用户合同后,系统自动生成优化的主生产计划、要料计划和机组作业计划,在生产过程中,系统对生产状况进行全面跟踪,对出现的异常情况进行合理调度,并且,冷轧MES与上游厂、公司ERP、过程控制系统和厂级管理系统连成一体,协同工作。该软件在实际应用中取得了令人满意的效果。

Undersökning av steady state och utvärdering av valskraft och friktion vid kallvalsning av aluminium

The purpose with this thesis was to examine the cold rolling mill located at Högskolan Dalarna and to stabilize the rolling process, to achieve steady state. Experiments with cold rolling of an aluminium strip have given results for rolling force, friction, reduction, strip tension and strain hardening. Results show that steady state has been found for the experiments with roll force and strain hardening, and not been found for the experiments with friction and reduction. Results show that increased strip tension gives lower roll forces. The roll force equation of Stone shows comparable results with reality for dry contact with reductions up to 30 %, but starts being incomparable with higher reductions. The roll force equation of Stone shows a bit higher roll forces than reality gave, but was comparable within reductions from 13 to 50 %. Experiments have shown that the aluminium strip has gone through strain hardening. Experiments show how the set roll gap did not yield the desired thickness reduction, there for the elastic spring constant for the rolling mill was examined and determined to be 417 N / mm for the specific alloy band. The influence of tension strip for roll force was examined and Results confirm the theory about how the roll force is decreased by increasing tension strip. The work rolls started to slip against the alumina strip as high tension strip; 70 N/mm2, gave low roll force; < 15kN.

The effect of prestrain and bake hardening on the low-cycle fatigue properties of TRIP steel

The scope of this study was to examine the effects of plane strain prestrain, induced via cold-rolling, and subsequent automotive paint bake hardening cycle on both tensile and fatigue properties of a hot rolled TRIP780 multiphase steel. Strain-life data has been generated for as-received (0% prestrain), 10% and 20% prestrained samples, in both baked and unbaked conditions. Cold rolling  increased the number of strain reversals to failure at high cyclic strain amplitudes with no effect at low strain amplitudes. Bake hardening increased the number of reversals to failure at high cyclic strain amplitudes. The prestrained material exhibited partial cyclic softening, with some residual strength increase. The residual strength increase was attributed to the austenite to martensite transformation that occurred during the prestraining process.

Effect of grain size on deformation twinning behaviour of high MN steel

The effect of grain size on the mechanical properties and deformation twinning behaviour in high manganese steel was investigated. In order to generate different grain sizes, the samples were subjected to hot rolling, cold rolling and annealing. Room temperature tensile testing of the steel with different grain sizes (5-50 µm) indicated the occurrence of twinning induced plasticity (TWIP) in all the samples. Also, changes in work-hardening behaviour accompanied changes in the grain size. The results are discussed in terms of the enhanced sensitivity of twinning to the grain size.

Fuzzy neural networks for control of dynamic systems

This thesis provides a unified and comprehensive treatment of the fuzzy neural networks as the intelligent controllers. This work has been motivated by a need to develop the solid control methodologies capable of coping with the complexity, the nonlinearity, the interactions, and the time variance of the processes under control. In addition, the dynamic behavior of such processes is strongly influenced by the disturbances and the noise, and such processes are characterized by a large degree of uncertainty. Therefore, it is important to integrate an intelligent component to increase the control system ability to extract the functional relationships from the process and to change such relationships to improve the control precision, that is, to display the learning and the reasoning abilities. The objective of this thesis was to develop a self-organizing learning controller for above processes by using a combination of the fuzzy logic and the neural networks. An on-line, direct fuzzy neural controller using the process input-output measurement data and the reference model with both structural and parameter tuning has been developed to fulfill the above objective. A number of practical issues were considered. This includes the dynamic construction of the controller in order to alleviate the bias/variance dilemma, the universal approximation property, and the requirements of the locality and the linearity in the parameters. Several important issues in the intelligent control were also considered such as the overall control scheme, the requirement of the persistency of excitation and the bounded learning rates of the controller for the overall closed loop stability. Other important issues considered in this thesis include the dependence of the generalization ability and the optimization methods on the data distribution, and the requirements for the on-line learning and the feedback structure of the controller. Fuzzy inference specific issues such as the influence of the choice of the defuzzification method, T-norm operator and the membership function on the overall performance of the controller were also discussed. In addition, the e-completeness requirement and the use of the fuzzy similarity measure were also investigated. Main emphasis of the thesis has been on the applications to the real-world problems such as the industrial process control. The applicability of the proposed method has been demonstrated through the empirical studies on several real-world control problems of industrial complexity. This includes the temperature and the number-average molecular weight control in the continuous stirred tank polymerization reactor, and the torsional vibration, the eccentricity, the hardness and the thickness control in the cold rolling mills. Compared to the traditional linear controllers and the dynamically constructed neural network, the proposed fuzzy neural controller shows the highest promise as an effective approach to such nonlinear multi-variable control problems with the strong influence of the disturbances and the noise on the dynamic process behavior. In addition, the applicability of the proposed method beyond the strictly control area has also been investigated, in particular to the data mining and the knowledge elicitation. When compared to the decision tree method and the pruned neural network method for the data mining, the proposed fuzzy neural network is able to achieve a comparable accuracy with a more compact set of rules. In addition, the performance of the proposed fuzzy neural network is much better for the classes with the low occurrences in the data set compared to the decision tree method. Thus, the proposed fuzzy neural network may be very useful in situations where the important information is contained in a small fraction of the available data.

Influence of deformation-induced heating on the bond strength of rolled metal multilayers

The bond strength of various metal multilayers produced by cold rolling of metal foils with different thermal conductivity was investigated. Results indicated that 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.

Development of the multi-scale analysis model to simulate strain localization occurring during material processing

Abstract A detailed description of possibilities given by the developed Cellular Automata—Finite Element (CAFE) multi scale model for prediction of the initiation and propagation of micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented in the work. Particular emphasis in defining the criterion for initiation of micro shear and shear bands, as well as in defining the transition rules for the cellular automata, is put on accounting for the physical aspects of these phenomena occurring in two different scales in the material. The proposed approach led to the creation of the real multi scale model of strain localization phenomena. This model predicts material behavior in various thermo-mechanical processes. Selected examples of applications of the developed model to simulations of metal forming processes, which involve strain localization, are presented in the work. An approach based on the Smoothed Particle Hydrodynamic, which allows to overcome difficulties with remeshing in the traditional CAFE method, is a subject of this work as well. In the developed model remeshing becomes possible and difficulties limiting application of the CAFE method to simple deformation processes are solved. Obtained results of numerical simulaA detailed description of possibilities given by the developed Cellular Automata—Finite Element (CAFE) multi scale model for prediction of the initiation and propagation of micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented in the work. Particular emphasis in defining the criterion for initiation of micro shear and shear bands, as well as in defining the transition rules for the cellular automata, is put on accounting for the physical aspects of these phenomena occurring in two different scales in the material. The proposed approach led to the creation of the real multi scale model of strain localization phenomena. This model predicts material behavior in various thermo-mechanical processes. Selected examples of applications of the developed model to simulations of metal forming processes, which involve strain localization, are presented in the work. An approach based on the Smoothed Particle Hydrodynamic, which allows to overcome difficulties with remeshing in the traditional CAFE method, is a subject of this work as well. In the developed model remeshing becomes possible and difficulties limiting application of the CAFE method to simple deformation processes are solved. Obtained results of numerical simulations are compared with the experimental results of cold rolling process to show good predicative capabilities of the developed model.tions are compared with the experimental results of cold rolling process to show good predicative capabilities of the developed model.