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Parameters analysis and process optimization of shell precision thermoforming

International Journal for simulation and Multidisciplinary Design Optimization 2025年 16卷

作者： Cheng, Haozhe Xu, Shubo Sun, Kangwei Wang, Shengliang Pan, Yuefei Ma, Hailong Ren, Guocheng Li, Jianing Zhao, Zhongkui Shandong Jianzhu University School of Materials Science and Engineering Jinan250101 China Huazhong University of Technology State Key Laboratory of Material Forming and Mould & Die Technology Wuhan430025 China

In this study, the aluminium alloy shell forming process is firstly studied and analysed. After that, the three-dimensional modelling software SOLIDWORKS is used to analyse and model the workpieces and the convex and concave dies of each process of the aluminium alloy shell hot extrusion forming process. Finally, the three-dimensional finite element numerical simulation software DEFORM-3D is used to carry out numerical simulation analysis on the precision hot forming process of aluminium alloy shell. Equivalent force and strain distributions, along with stroke-load curves, were analyzed under varying conditions by changing the friction factor and forming temperature. The simulation results show that under the conditions of friction factor of 0.25 and temperature of 450°C, it is most suitable for the machining of aluminium alloy shell hot extrusion forming process. © H. Cheng et al., Published by EDP Sciences, 2025.

关键词： Thermoforming

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Parametric modeling and simulation analysis of porous materials prepared by 3D printing technology

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International Journal for simulation and Multidisciplinary Design Optimization 2025年 16卷

作者： Li, Tianhua Ma, Hailong Xu, Shubo Liu, Renhui Pan, Yuefei Ren, Guocheng Li, Jianing Zhao, Zhongkui Shandong Jianzhu University School of Materials Science and Engineering Jinan250101 China Huazhong University of Technology State Key Laboratory of Material Forming and Mould & Die Technology Wuhan430025 China

The study in this paper is the modeling as well as simulation analysis of porous materials prepared by 3D printing technique. The structural simulation analysis of porous material is carried out using ANSYS Workbench 15.0 to derive the deformation as well as stress distribution. Based on the simulation results the equivalent elastic modulus of the porous material is calculated under the homogenization theory. The effect of different parameters on the mechanical properties of the porous material is analyzed, and the most suitable model parameters are compared with the elastic modulus of human bone. The analysis results show that the main factor affecting the mechanical properties of porous materials is the porosity, and the secondary factor is the properties of the materials themselves. The nickel-based alloy tetrahedral porous material can reach the level of human cortical bone when the porosity reaches 70-87%, and the titanium alloy tetrahedral porous material can reach the range of 60-70% porosity. When the porosity of titanium alloy tetrahedral porous material reaches 87% level, it can reach the level of human cancellous bone. © T. Li et al., Published by EDP Sciences, 2025.

关键词： Titanium alloys

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Surface Microstructure Refinement and Mechanical Properties of Gcr15 Steels Improved During Ultrasonic Surface Rolling Processing

SSRN

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SSRN 2022年

作者： Xue, Xianmeng Xu, Shubo Ma, Xiquan Han, JuanJuan Zheng, Wei School of Materials Science and Engineering Shandong Jianzhu University Jinan250101 China State Key Laboratory of Material Forming and Mould & Die Technology Central China University of Technology Wuhan430025 China

As one of the most commonly used high chromium-bearing steels, GCr15 steel (AISI-52100) has high hardness, strength, wear resistance, and corrosion resistance. However, the surface of GCr15 steel is sensitive to failure behavior. In this paper, ultrasonic surface rolling processing (USRP) was used to strengthen GCr15-bearing steel. A finite element three-dimensional model of USRP was established to analyze the residual compressive stress and equivalent plastic strain distribution on the bearing steel surface. The microstructure, hardness, surface roughness, and corrosion resistance before and after USRP treatment were characterized by SEM, EBSD, X-ray diffraction (XRD), and electrochemical techniques. Results indicated that USRP treatment can significantly improve the material's surface microstructure and residual compressive stress distribution and obtain a plastic strain layer of about 60μm. After USRP treatment, the Kernel Average Misorientation (KAM) increased, and the dislocation activity was more intensive, resulting in aggregation near grain boundaries, and the percentage of LAGBs increased to 38.8%. Under the combined effect of surface grain refinement, residual compressive stress, and high glossy surface, the self-corrosion current density is reduced by two orders of magnitude, and the corrosion resistance is significantly improved. This investigation suggests a solution to the bearing failure problem and has implications for understanding the deformation mechanism of ultrasonic surface rolling processing. © 2022, The Authors. All rights reserved.

关键词： Corrosion resistance

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Modulation of Ti2Ni morphology in laser powder bed fused Ni-Ti alloys for excellent shape memory effect

SSRN

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SSRN 2024年

作者： Ma, Bowen Lu, Haizhou Li, Jiayin Chen, Dongxu Jiang, Yuchuan Yang, Chao Li, Dongdong Zhang, Yuping State Key Laboratory for Materials Processing and Die and Mould Technology School of Materials Science and Engineering Huazhong University of Science and Technology Wuhan China School of Mechatronic Engineering Guangdong Polytechnic Normal University Guangzhou510665 China National Engineering Research Center of Near-net-shape Forming for Metallic Materials South China University of Technology Guangzhou510640 China School of Chemistry and Chemical Engineering Huazhong University of Science and Technology Wuhan China

NiTi alloy produced by laser powder bed fusion (LPBF) is often limited by uncontrolled non-equilibrium solidification, which generates non-uniform tissue such as Ti2Ni with irreversible effects on its mechanical and functional properties. To address this challenge, a layer-alternating LPBF (ALT-LPBF) method that programs hs changes along the building height was proposed for the first time. ALT-LPBF enables directional control over the morphology of Ti2Ni (from spherical to sub-ellipsoidal) by influencing inhomogeneous residual stress. Precise testing of the compositional fields within the melting pool and grains revealed that both peritectic and eutectic reactions are involved in Ti2Ni development, contributing to a deeper understanding of the mechanisms governing Ti2Ni formation during ALT-LPBF. Additionally, spherical Ti2Ni forms a coherent interface with B2 matrix, reducing stress concentration and promoting work hardening, through an elastic strain field. In contrast, sub-ellipsoidal Ti2Ni forms an incoherent interface, intensifying the stress field, promoting dislocation accumulation and inhibiting plastic deformation. The combination of spherical and sub-ellipsoidal Ti2Ni induced by ALT-LPBF enhances ultimate tensile strength to 850.6 MPa and shape memory effect 98.8%. This work lays the foundation for achieving ideal shape memory effect through ALT-LPBF and expands biomedical devices and smart materials applications. © 2024, The Authors. All rights reserved.

关键词： Tensile testing

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Macro-Micro Behaviors of Ti-22al-26nb Alloy During Warm Tension

SSRN

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SSRN 2022年

作者： Zhang, Xiao-Li Yan, Si-Liang Meng, Miao Li, Ping School of Materials Science and Engineering Engineering Research Center of High Performance Copper Alloy Materials and Processing Ministry of Education Hefei University of Technology 193 Tunxi Road Hefei230009 China State Key Laboratory of Materials Processing and Die & Mould Technology Huazhong University of Science and Technology Wuhan430074 China Shaanxi Key Laboratory of High-performance Precision Forming Technology and Equipment Northwestern Polytechnical University Xi’an710072 China

In this paper, the plastic flow rules and fracture evolution mechanisms of the nearlyO+B2 Ti-22Al-26Nb alloy during warm tensile have been studied within a widetemperature range of 20~800°C. The macro and micro deformation behaviors and themicro-mechanisms of the material under tensile deformation have been investigated bymeans of SEM, EBSD and TEM. It is found that the stress-strain curve exhibitsserrated patterns at 400°C, indicating the occurrence of dynamic strain aging at mildtemperature. The overall yield strength decreases and the uniform elongationincreases with the temperature in general. However, an unexpected peak of yieldstrength and also an unexpected valley of uniform elongation are exhibited at 600°***, the uniform elongation shows positive strain rate sensitivity at 600°C. Withthe comprehensive analyses of fracture surface characteristics, the morphologicalvariation of the constituent phases and the dislocation structure evolution, thecausations of the above phenomena are further explained as follows. The B2 phase ismainly responsible for deformation coordination between O laths with the original{110}B2(001)O orientation barely changed, and act as a media for propagatinglocalized slip deformation to O grains. The abnormal mechanical responses at 600°Care mainly attributed to the change of fracture mode caused by the precipitation of fineacicular O grains, while the softening mechanism at 800°C is mainly dominated by thedynamic globularization of O phase. © 2022, The Authors. All rights reserved.

关键词： Aluminum alloys

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simulation of casting filling process using the lattice Boltzmann method

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IOP Conference Series: Materials Science and Engineering 2019年第1期529卷

作者： Y J Zhang X W Qian J X Zhou Y J Yin X Shen X Y Ji J L Huang State Key Laboratory of Material Processing and Die & Mould Technology Huazhong University of Science and Technology Wuhan 430074 China Advanced Forming Research Centre University of Strathclyde 85 Inchinnan Drive Renfrew PA4 9LJ United Kingdom

Numerical simulation of casting filling process with complex shape is time-consuming. Compared with the traditional SOLA-VOF method, the lattice Boltzmann method (LBM) calculates the pressure field by particle distribution functions instead of the correction of the velocity and pressure fields, which greatly simplifies the calculation process. In addition, the LBM provides a flexible approach which can be easily parallelized. In this study, the LBM is employed to simulate casting filling process. An implementation of a volume-of-fluid (VOF) method within the lattice Boltzmann framework is proposed to capture the free surface of the casting filling process. A Smagorinsky large eddy simulation (LES) model is adopted to improve the numerical stability of the LBM. An adaptive time stepping technique is implemented to ensure an efficient and stable simulation. The model is validated by the experimental and simulation results of Campbell box filling process. The filling process of complex casting is simulated, and the result is compared with the filling process obtained by the SOLA-VOF method. The prediction accuracy and reliability of free surface profile is analysed.

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Heat transfer and stress evolution behaviours of an aluminium alloy low pressure shell casting

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IOP Conference Series: Materials Science and Engineering 2015年第1期84卷

作者： D Q Zhang J X Zhou T Chen J. X. Zhou Male Professor Ph.D. His research interests mainly focus on the computer applications in foundry especially on casting process simulation and informatization for foundry enterprise State Key Laboratory of Material Processing and Die & Mould Technology Huazhong University of Science and Technology Wuhan 430074 Hubei China

Considering the solidification, demoulding and heat treatment processes in low pressure casting, relatively complete processes of an aluminium alloy shell casting are simulated to investigate the heat transfer feature and stress behaviours variation of casting in each multi-processes stage. FDM is used to discrete thermal conduction model when studying the heat transfer process, while FEM is adopted to solve the elastic-plastic model when studying the stress behaviour variation. When matching the two models, we map the finite difference mesh to finite element mesh. Three different temperature conditions, namely 300 °C, 400 °C and 500 °C, are simulated when we research the influence of demoulding temperature on stress behaviour. The simulation results demonstrate that the higher demoulding temperature is, the greater casting deformation and the smaller stress value are. The final casting stress status and the initial heat treatment temperature have a different relationship as for different parts of casting.

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Atomic simulation of size effect and surface properties of aluminum nanoparticles

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2013 2nd International Conference on Sport Material, Modelling and simulation, ICSMMS 2013

作者： Zhu, Wei Song, Wulin Wang, Jianjun State Key Lab of Materials Forming Simulation and Die and Mould Technology Huazhong University of Science and Technology Wuhan 430074 China

ISBN: (纸本)9783037856635

Here, modified analytic embedded atom method (MAEAM) has been utilized to simulate size effect and surface properties of aluminum (Al) nanoparticles. According to the simulation results, we can find that lattice parameter and excess stored energy are size dependent. The simulated excess stored energy ranges from 2.12 to 57.61 kJ/mol, which is in the same order of magnitude with experiment results;surface energy of Al nanoparticles ranges from 0.78 to 1.10 J/m2, which is not invariant but size related. Furthermore, non-uniform lattice distortion has been observed in Al nanoparticles, and mainly concentrates in the first and second shell of surface layers. Theoretical research based on our simulation results provides a novel method to predict excess stored energy of metallic nanoparticles. © (2013) Trans Tech Publications, Switzerland.

关键词： Molecular dynamics

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Atomic simulation of Size Effect and Surface Properties of Aluminum Nanoparticles

Atomic Simulation of Size Effect and Surface Properties of A...

引用

2013 International Conference on Sport Material,Modelling and simulation(ICSMMS 2013)

作者： Wei Zhu Wulin Song Jianjun Wang State Key Lab of Materials Forming Simulation and Die and Mould Technology Huazhong University of Science and Technology

Here, modified analytic embedded atom method(MAEAM) has been utilized to simulate size effect and surface properties of aluminum(Al) nanoparticles. According to the simulation results, we can find that lattice parameter and excess stored energy are size dependent. The simulated excess stored energy ranges from 2.12 to 57.61 k J/mol, which is in the same order of magnitude with experiment results;surface energy of Al nanoparticles ranges from 0.78 to 1.10 J/m2, which is not invariant but size related. Furthermore, non-uniform lattice distortion has been observed in Al nanoparticles, and mainly concentrates in the first and second shell of surface layers. Theoretical research based on our simulation results provides a novel method to predict excess stored energy of metallic nanoparticles.

关键词： Molecular dynamics simulation Size effect Surface energy Non-uniform lattice distortion Excess stored energy Aluminum nanoparticles

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Effect of cerium on abrasive wear behaviour of hardfacing alloy

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Journal of Rare Earths 2012年第1期30卷 69-73页

作者： XING Shule YU Shengfu DENG Yu DAI Minghui Yu Lu State Key Laboratory of Material Forming and Mould&Die Designing Huazhong University of Science and TechnologyWuhan 430074China

Hardfacing alloys with different amounts of ceria were prepared by self-shielded flux cored arc *** abrasion tests were carried out using the dry sand-rubber wheel machine according to JB/T 7705-1995 *** hardness of hardfacing deposits was meas-ured by means of HR-150AL Rockwell hardness test and the fracture toughness was measured by the indentation *** characterization and surface analysis were made using optical microscopy,scanning electron microscopy（SEM） and energy spectrum *** results showed that the wear resistance was determined by the size and distribution of the carbides,as well as by the matrix *** main wear mechanisms observed at the surfaces included micro-cutting and micro-ploughing of the *** addition of ceria improved the hardness and fracture toughness of hardfacing deposits,which would increase the resistance to plastic deformation and scratch,thus the wear resistance of hardfacing alloys was improved.

关键词： abrasive wear carbides rare earth oxides

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