Numerische Prozessauslegung zur gezielten Eigenspannungseinstellung in warmmassivumgeformten Bauteilen unter Berücksichtigung von Makro- und Mikroskala

Behrens, Bernd‐Arno; Schröder, Jörg; Brands, Dominik; Brunotte, Kai; Wester, Hendrik; Scheunemann, Lisa; Uebing, Sonja; Kock, Christoph

doi:10.1007/s10010-021-00482-x

Cited by 3 publications

(9 citation statements)

References 14 publications

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“…Fig. 1: a) Spray cooling device with six independent nozzles that provides temporal and spatial control of the cooling process, taken from [17]. b) Cylindrical specimen in initial and final configuration, provided by IFUM.…”

Section: A) B)mentioning

confidence: 99%

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Numerical investigation of hot bulk forming processes with respect to the resulting residual stress distribution

Hellebrand

Brands

Scheunemann

et al. 2023

Proc Appl Math and Mech

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The cost‐ and time‐efficient design of today's manufacturing processes is closely linked to numerical simulations. By developing and applying suitable simulation models, component properties can be specifically predicted and, if necessary, modified according to the customer's specifications. One important aspect of this is the adjustment towards advantageous residual stress profiles, for example to increase service life or wear resistance. Hot forming processes offer the advantage of the interaction of thermal, mechanical and metallurgical effects. In particular, cooling after prior heating and forming, in this case upsetting, results in a phase transformation on the microscale in the material. The residual stress state, which arises from dislocations in the atomic lattice, will be considered in more detail in this contribution.Here, the focus lies on the analysis of microscopic characteristics utilizing a multi‐scale Finite Element model in terms of a FE2 approach.

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Section: A) B)mentioning

confidence: 99%

“…Therefore, this contribution focuses on the use of a spray cooling device as shown in Figure 1a, which has shown promising results, see e.g. [16,17]. For the considered cooling route, only one nozzle is active, which applies the spray as mixture of water and air on the thick side of the component.…”

Section: Hot Bulk Forming Processmentioning

confidence: 99%

Numerical investigation of hot bulk forming processes with respect to the resulting residual stress distribution

Hellebrand

Brands

Scheunemann

et al. 2023

Proc Appl Math and Mech

Self Cite

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“…In this context, [26] showed that induced compressive residual stresses in regions of high tensile loading can improve the performance and extend the operating time. As showed in [16], cooling with a spray device with one nozzle directed to the thick-walled side seems promising in order to obtain the targeted stress state. The remaining stresses that occur inside the material as a consequence of the cooling of the cylindrical specimen with a spray are interpreted as macroscopic residual stress in absence of outer forces and if the temperature gradient vanishes, that is, if room temperatures is achieved in the complete component.…”

Section: Macroscopic Residual Stress Analysismentioning

confidence: 99%

“…After the heating step, the forming reduces the height of the specimen by approximately 50%. Previous works [5, 16–19] showed that the application of different cooling media (air, water, spray) or routes (various spray cones) leads to different residual stress states. It was found that a spray cooling with a mixture of water and air, that lasts for 300 s results in the targeted stress state showing compressive stresses in regions near the outer surface of the cylinder [16, 18].…”

Section: Hot Bulk Forming Processmentioning

confidence: 99%

“…Previous works [5, 16–19] showed that the application of different cooling media (air, water, spray) or routes (various spray cones) leads to different residual stress states. It was found that a spray cooling with a mixture of water and air, that lasts for 300 s results in the targeted stress state showing compressive stresses in regions near the outer surface of the cylinder [16, 18]. Here, only one nozzle is activated, applying the spray on the thick‐walled side of the component (cf.…”

Section: Hot Bulk Forming Processmentioning

confidence: 99%

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On the three‐dimensional numerical analysis of residual stresses on two scales in hot bulk forming parts

Hellebrand,

Brands,

Schröder

2023

Proc Appl Math and Mech

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Current research focuses on the induction of residual stresses in a component during its manufacturing process, which shows a significant impact on the final component's properties. During the manufacturing of a hot bulk forming component, the temperature evolution allows to influence the resulting residual stress state efficiently and purposefully. Following the characterization of residual stresses on different scales, single‐scale finite element simulations are carried out on macro‐ and microscale. In contrast to previous findings for two‐dimensional boundary value problems, the effects of the third dimension are demonstrated. Furthermore, it is shown that the residual stress distribution is effectively influenced by choosing different cooling routes in targeted manner. Eventually, the importance of microscopic residual stress investigations is discussed.

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Methodology to Investigate the Transformation Plasticity for Numerical Modelling of Hot Forging Processes

Behrens

Brunotte

Wester

et al. 2022

KEM

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Hot forging is a complex process involving the mutual influence of numerous thermo-mechanical-metallurgical material phenomena. In particular, the strains of transformation-induced plasticity (TRIP) have a significant influence on the distortions and residual stresses of the components. The TRIP strains refer to the anisotropic strains depending on the orientation and significance of the stress conditions during cooling superimposed to the phase transformation. With the use of numerical models, the impact of this effect can be investigated in order to ensure the production of high quality components. However, an experimental determination of the characteristic values of TRIP is challenging, which is why only few corresponding data are available in the literature. Therefore, this paper presents an experimental and numerical methodology as well as the results of studies on the interaction between stresses and phase transformations in the materials AISI 4140 and AISI 52100. The investigations of the TRIP strains are carried out using hollow specimens, which are thermo-mechanically treated in the physical forming simulator Gleeble 3800-GTC. The specimens are austenitised, quenched to test temperature and held there while diffusion controlled phase transformation takes place. The extent of TRIP as a result of different superimposed tensile or compressive loads is determined by means of dilatometry. In addition, the extent of TRIP for diffusionless martensitic phase transformations was investigated by continuous cooling tests under tensile and compressive loads. It was found that the transformation plasticity varies depending on the material, the phase type, the temperature and the tensile or compressive stresses. Subsequently, simulations of the physical experiments using the FE software Simufact.Forming verified the determined phase specific values of TRIP.

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Numerische Prozessauslegung zur gezielten Eigenspannungseinstellung in warmmassivumgeformten Bauteilen unter Berücksichtigung von Makro- und Mikroskala

Cited by 3 publications

References 14 publications

Numerical investigation of hot bulk forming processes with respect to the resulting residual stress distribution

Numerical investigation of hot bulk forming processes with respect to the resulting residual stress distribution

On the three‐dimensional numerical analysis of residual stresses on two scales in hot bulk forming parts

Methodology to Investigate the Transformation Plasticity for Numerical Modelling of Hot Forging Processes

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