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In this work a numerical procedure, based on a finite element approach, is proposed to simulate multiple three-dimensional crack propagation in a\ud
welded structure. Cracks are introduced in a friction stir welded AA2024-T3 butt joint, affected by a process-induced residual stress scenario. The\ud
residual stress field was inferred by a thermo-mechanical FEM simulation of the process, considering temperature dependent elastic-plastic material\ud
properties, material softening and isotropic hardening. Afterwards, cracks introduced in the selected location of FEM computational domain allow\ud
stress redistribution and fatigue crack growth. The proposed approach has been validated by comparison with numerical outcomes provided by a\ud
consolidated FEM-DBEM procedure, available in literature. The discussed procedures are substantially equivalent in terms of SIFs evaluation along\ud
the crack front at the cracks insertion, as well as with respect to crack sizes measured in three different points for each propagation step. This FEMbased\ud
approach simulates the fatigue crack propagation by considering accurately the residual stress field generated by plastic deformations imposed\ud
on a structural component and has general validity
Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. On the other hand, processes which inherently may seem multiphysical by nature might sometimes be modelled by considerably simpler models if the problem at hand can be somehow adequately simplified. In the present article, examples of this will be presented. The cases are chosen with the aim of showing the diversity in the field of modelling of manufacturing processes as regards process, materials, generic disciplines as well as length scales: (1) modelling of tape casting for thin ceramic layers, (2) modelling the flow of polymers in extrusion, (3) modelling the deformation process of flexible stamps for nanoimprint lithography, (4) modelling manufacturing of composite parts and (5) modelling the selective laser melting process. For all five examples, the emphasis is on modelling results as well as describing the models in brief mathematical details. Alongside with relevant references to the original work, proper comparison with experiments is given in some examples for model validation.
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