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Multiple process microstructure evolution simulation of ultrasonic assisted rolling directed energy deposition

MATERIALS & DESIGN 2023年第1期231卷

作者： Li, Hao Xu, Hongtu Fei, Liangyu Tian, Tiantai Han, Bin Zhang, Qi Xi An Jiao Tong Univ Sch Mech Engn Xian 710049 Shaanxi Peoples R China

Directed energy deposition (DED) has a widely application prospect, but dendrite and component segregation are not easily controlled and predicted. In this study, the method of applying ultrasonic assisted rolling was introduced to the DED to eliminate above phenomenon. A multiple process microstructure evolution simulation (involved melting, solidification, dynamitic recrystallization and grain growth) was also carried out, which introduced ultrasonic effect in the form of energy. The influence of ultrasonic amplitude (A), distance between laser focus point and ultrasonic roller (d0) on microstructure of Pb-Sn alloy deposition layer were explored. There is a good consistency between experiment and simulation with relative error of 4.33%. The results show that the roundness of grains is improved significantly after rolling, and the grain are refined with the increase of A and d0. In all tests of this study, comprehensive effect of ultrasonic rolling achieves the best when d0 is taken as 24 mm and A is taken as 20 lm, the average grain diameter (D0) in grain size counted zone is 18.8 lm which is 23.23% lower than that without rolling. This study laid a foundation for the development of ultrasonic assisted rolling DED and provide a multiple process microstructure simulation method.& COPY;2023 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://***/licenses/by-nc-nd/4.0/).

关键词： Directed energy deposition Ultrasonic assisted rolling microstructure evolution simulation Dynamic recrystallization

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Numerical simulation for microstructure evolution and Shear Properties of Magnetorheological Gels

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ACS APPLIED POLYMER MATERIALS 2023年第5期5卷 3737-3748页

作者： Huang, Hongzhi Li, Haitao Peng, Xianghe Chongqing Univ State Key Lab Coal Mine Disaster Dynam & Control Chongqing 400044 Peoples R China Chongqing Univ Coll Aerosp Engn Chongqing 400044 Peoples R China China Acad Engn Phys Inst Appl Phys & Computat Math Beijing 100000 Peoples R China

The rheological properties and shear performance of magnetorheological (MR) gels have been extensively studied based on experimental methods. However, viscoelastic theoretical models that can quantify the interaction between the matrix and particles, as well as numerical simulations on the mechanical properties and the microstructure evolution of MR gels, are still relatively few and need to be further investigated. In this paper, based on the non-Newtonian fluid equation and Kelvin viscoelastic model, a modified viscoelastic resistance model is proposed, which can describe the interaction between the matrix and particles. The consistency coefficient, flow behavior index, particle size, and motion velocity are considered comprehensively in the viscoelastic resistance equation. Based on the established theoretical model, the numerical simulation approach is developed to study the evolution of chain-like microstructures and the shear properties of MR gels. The response time of MR gels under different magnetic fields and matrixes is analyzed from the perspective of energy. It shows that the effect of magnetic field intensity on the shear strength of MR gels is consistent with the magnetization characteristics of particles. The maximum shear stress and flow stress are significantly affected by viscosity parameters of the matrix and shear rate, which are related to the strength of shear-bearing chains and recombination rate of dissociative chains. The relevant influence mechanism of the microstructures on the macroshear properties is explored.

关键词： magnetorheological gel modified viscoelastic resistance microstructure evolution simulation shear characteristics micro-macromechanism

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Design of spark plasma sintering parameters and preparation of Al2O3/TiB2/TiC micro-nano composite ceramic tool material

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INTERNATIONAL JOURNAL OF APPLIED CERAMIC TECHNOLOGY 2023年第3期20卷 1420-1431页

作者： Wang, Dong Bai, Yifan Qiu, Bo Yu, Hongtao Li, Zhibao Xian Technol Univ Sch Mech Engn Xian 710021 Peoples R China Aecc Xian Aeroengine Ltd Xian Peoples R China

A microstructure evolution model for the ceramic materials was constructed, and the spark plasma sintering parameters were optimized using the model to shorten the designing period and reduce the consumption of the material. Based on the optimized sintering parameters, the ceramic tool material with a composition of Al2O3, TiB2, and TiC proved to be a success. It verified that the materials prepared under the optimized sintering parameters exhibited excellent mechanical properties. The results showed when sintered at 1600 degrees C, under the pressure of 40 MPa and with the holding period of 7 min, the materials with 70% Al2O3, 20% TiB2, and 10% nano-TiC possess the relatively best performance, with the hardness, fracture toughness, and flexure strength being 20.3 GPa, 10.5 MPa/m(2), and 839.5 MPa, respectively.

关键词： cellular automata ceramic tool microstructure evolution simulation sintering parameters design spark plasma sintering

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simulation of the evolutions in Real microstructure of Material under Thermal Cycle with High Thermal Gradients

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Procedia CIRP 2020年 95卷 238-243页

作者： T. Bergs M. Mohammadnejad R. Hess L. Heidemanns A. Klink Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

The microstructure evolution induced in the workpiece during a manufacturing process influences the functionality of the final product. Therefore, there is a high interest for prediction of the induced microstructure evolution in surface and sub-surface layers of the workpiece. Up to the present day, determination of the final state of microstructure is mostly based on the personal experience obtained from numerous experiments. The microstructure evolution simulation is an alternative to the old trial and error approaches. The recent developments in the computational capacity lead to considerable advances in the material simulation science. In the previous years the authors of this work used the phase field approach for modeling of the microstructure evolution in a steel workpiece under thermal cycle with high temperature gradients. As follow up to the previous works, the presented model is modified to be adjustable for real microstructure of material as well as considerably higher temperature gradients. This model can further be used for modeling of the microstructure evolution during processes with main thermal impact. To evaluate the phase field model, the results of simulations were compared with the experimental data.

关键词： reverse simulation single dischatge material modification microstructure evolution simulation electrical discharge machining (EDM)

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Phase Field Modeling of the microstructure evolution in a Steel Workpiece under High Temperature Gradients 4th

Phase Field Modeling of the Microstructure Evolution in a St...

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4th CIRP Conference on Surface Integrity (CSI)

作者： Klocke, F. Mohammadnejad, M. Hess, R. Harst, S. Klink, A. Rhein Westfal TH Aachen Lab Machine Tool & Prod Engn WZL Steinbachstr 19 D-52074 Aachen Germany

Electrical discharge machining (EDM) is an ablative process with main thermal active principle. The applied thermal energy during this process leads to microstructure modifications in the rim zone of the eroded workpiece. These induced microstructure modifications directly affect the functionality of the workpiece. Nevertheless, these modifications cannot be easily predicted. Therefore, finding new methods for prediction of these modifications is of great interest both in academia and in industry. The microstructure modifications in the rim zone of an eroded workpiece are partly results of liquid-solid phase transformations in the recast layer and solid-solid phase transformations in the heat affected zone (HAZ). Therefore, by simulation of the microstructure evolution in these regions, their final microstructure can be predicted. Despite of the recent advances in the material simulation science, only few studies on simulation of microstructure evolution during EDM can be found in literature. This can be explained by the high temperature and temperature gradients that act during this process. These extreme boundary conditions evoke different complexities during material simulations. In this work, the complexities, which appear during the simulation of microstructure evolution for EDM are addressed. Furthermore, a simulation model for description of the microstructure evolution in a steel material under high temperature gradients is developed. The developed model is based on the phase field approach. Due to the potentials of this mathematical approach in describing the kinematics of multiphase systems, it became an attractive method for simulation of microstructure evolution. Although, the implemented temperature gradients are lower than the actual values, this model can be later used for simulation of the microstructure evolution in the HAZ of an eroded workpiece. (C) 2018 The Authors. Published by Elsevier Ltd.

关键词： microstructure evolution simulation EDM Heat affected zone

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Investigation on the Variability of Existing Models for simulation of Local Temperature Field during a Single Discharge for Electrical Discharge Machining (EDM) 19

Investigation on the Variability of Existing Models for Simu...

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19th CIRP Conference on Electro Physical and Chemical Machining

作者： Klocke, Fritz Mohammadnejad, Mehnoush Zeis, Markus Klink, Andreas Rhein Westfal TH Aachen Lab Machine Tools & Prod Engn WZL Aachen Germany Fraunhofer Inst Prod Technol IPT Steibachstr 17 D-52074 Aachen Germany

In electrical discharge machining (EDM) material removal and rim zone modifications are resulted by generated heat during numerous discharges. By estimating the temperature field applied on the workpiece as material loading, removal rate and induced modifications in the rim zone can be predicted. Different scientists tried to simulate the induced temperature field on the workpiece during a single or multiple discharges. However, due to the complex removal mechanism in EDM, these models are mostly incomplete and contain considerable uncertainties. In this study, the strengths and weaknesses of typical heat transfer models for a single discharge are discussed. For this propose a finite element model is constructed and influences of different modeling parameters on the obtained results have been analyzed. Moreover, potentials of reverse microstructure simulation as an assistant for modification of heat source models discussed. (C) 2018 The Authors. Published by Elsevier B.V.

关键词： reverse simulation single dischatge material modification microstructure evolution simulation electrical discharge machining (EDM)

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Investigation on the Variability of Existing Models for simulation of Local Temperature Field during a Single Discharge for Electrical Discharge Machining (EDM)

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Procedia CIRP 2018年 68卷 260-265页

作者： Fritz Klocke Mehnoush Mohammadnejad Markus Zeis Andreas Klink Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology (IPT) Steibachstr 17 Aachen 52074 Germany

关键词： reverse simulation single dischatge material modification microstructure evolution simulation electrical discharge machining (EDM)

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Phase Field Modeling of the microstructure evolution in a Steel Workpiece under High Temperature Gradients

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Procedia CIRP 2018年 71卷 99-104页

作者： F. Klocke M. Mohammadnejad R. Hess S. Harst A. Klink Laboratory for Machine Tool and Production Engineering WZL of RWTH Aachen University Steinbachstrasse 19 52074 Aachen Germany

关键词： microstructure evolution simulation EDM Heat affected zone

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Sequential approximate optimization-based robust design of SiC-Si₃N₄ nanocomposite microstructures

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ENGINEERING OPTIMIZATION 2013年第3期45卷 287-309页

作者： Mejia-Rodriguez, Gilberto Renaud, John E. Kim, Han Sung Tomar, Vikas Univ Notre Dame Notre Dame IN 46556 USA Purdue Univ Sch Aeronaut & Astronaut W Lafayette IN 47907 USA

A simulation-based robust design optimization methodology to predict the most suitable microstructures of SiC-Si N-3 (4) nanocomposites for desired high-temperature toughness is presented. The focus is on finding robust nanocomposite microstructures with maximum toughness at two temperatures: 1500 degrees C and 1600 degrees C. Within this context a sequential approximate optimization algorithm under uncertainty is applied to six different test problems addressing different aspects of robust microstructure generation. During optimization, statistical uncertainties inherent to the computational microstructural generation are quantified and introduced in the optimization framework. The results show that the SiC volume fraction, the number of Si N-3 (4) grains, the grain size distribution of the Si N-3 (4) grains, and the grain size of the SiC particles have varied effects on the microstructure toughness at different temperatures. At 1500 degrees C, the preferred microstructure is the one with higher Si N-3 (4) volume fraction, whereas at 1600 degrees C, the preferred microstructure is the one with higher SiC volume fraction.

关键词： composite materials tailoring microstructure evolution simulation robust design sequential approximate optimization trust region methods

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The modulus mensuration of Yada model and the microstructure simulation of casting AZ31 magnesium alloy

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International Conference on Manufacturing Science and Engineering (ICMSE 2009)

作者： Li, Hongbo Lu, Mei Luo, Junting Yanshan Univ Coll Mech Engn Qinhuangdao Peoples R China

ISBN: (纸本)9780878492800

Both experimentation and calculation of the Yada model modulus of casting AZ31 magnesium alloy are provided in this paper. Based on revised Yada model, the microstructure simulation of precision forming inner gear is performed using Superform software. On the basisi of result analysis, the microstructure transformation of the casting magnesium alloy in the hot-forming process is forecasted in terms of revised Yada model.

关键词： magnesium alloy microstructure evolution simulation Yada model precision form

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