Papers by Keyword: Flow Curve

Abstract: Process maps according to Parasad et al. are already widely used to make statements about the formability of materials and their forming energy. However, these process maps only apply to conventional incompressible materials. At the TU Bergakademie Freiberg, these process maps have already been extended for particle-reinforced incompressible solid materials with a homogeneous particle distribution. The next step is to adapt the model for compressible particle-reinforced matertials so that they can also be used in powder metallurgy. The problem here is that the volume decreases as a result of compaction during powder forming. In powder metallurgy, however, compaction plays an important role. On the one hand, the compaction of the components leads to an increase in the material properties. On the other hand, pores pose a high risk of fractures and cracking. For this reason, it is the aim of this paper to make the existing process maps for incompressible materials usable for compressible materials by corresponding adaptations of the models prevailing in powder metallurgy. Furthermore, the effects of a homogeneous particle distribution and a graded particle distribution within the TRIP matrix composites on the process maps will be investigated. For this reason, process maps are produced in the temperature ranges between 700 – 1050 °C, with forming speeds of 0.001 – 100 s^-1 and residual porosity of 10 – 30 %. For this purpose, specimens with corresponding residual porosity and homogeneously distributed ZrO₂ 5 vol.%, 10 vol.%, 15 vol.% and 20 vol.% as well as a graded layer structure of corresponding ZrO₂ proportions are prepared. With the aid of these specimens, flow curves are determined and adjusted at appropriate temperatures and forming speeds during compression tests. The energy dissipation and an instability map are then modelled from these flow curves and a process map is derived. It was found that with increasing ZrO₂ content in the homogeneous and the graded structure, the areas that allow damage-free forming become smaller. The same applies with decreasing residual porosity. Nevertheless, the areas, which allow failure-free forming, are larger than the possible forming areas of solid components. However, the power dissipation efficiency of incompressible specimens is significantly lower than that of compressible specimen [1]. In addition, it was observed that with increasing ZrO₂ content and decreasing residual porosity, the efficiency of the power dissipation in the formable areas decreases. It was also found that the distribution of the reinforcing particles has a significant influence on the flow curves and the associated process maps, then the graded specimen do not represent a superposition of the individual process maps of the homogeneous specimens.

Abstract: Deformation behavior of an as-cast Mg-6.8Y-2.5Zn-0.4Zr alloy during plane strain compression was characterized in present work by high-temperature testing. Based on the experimental data, the values of strain rate sensitivity, efficiency of power dissipation and the instability parameter under the condition of various hot working parameters were investigated. Processing maps were established by superimposing the instability map over the power dissipation map, this being connected with microstructural evolution analysis in the hot deformation processes. Accompanied microstructure characterization of the binary α-Mg/ Long Period Stacking Ordered (LPSO) microstructure reveals that the flow behavior is related to the deformation mechanisms. At lower temperatures (350 – 400 °C) formation of kink bands is observed, which normally occur when deformation twinning is inhibited and other slip systems are strongly hindered by the complex LPSO structures. Dynamic recrystallization (DRX) was initiated at higher temperatures above 400 °C, influencing the softening behavior of the material significantly. DRX was the main softening mechanism when deformation takes place at 500 °C and the kink band deformation decreased.

Abstract: The present investigation aims at studying the flow behaviour of magnesium alloys under different conditions in terms of temperature, deformation velocities and deformation. The modelling approach was based on a proposed equation to model the shape of each flow curve through different variables. The modelled flow curves were subsequently compared with those obtained with experiments. The models were validated on flow curves not used in the building stage. It was observed that, for low temperature values, high deformation velocities and deformations the final part of the flow curve has to be adapted in order to be adopted for the description of material in the numerical simulation. In other words it needs to be extrapolated. Also for the high temperature, the flow softening has to be limited in order to allow the extrapolation queue required for elevated deformations. The deformation value at which the extrapolation can start can be predicted with an other proposed equation detailed in the paper.

Abstract: Automotive parts made of ultra-high strength steels (UHSS) have been increasingly produced by hot stamping or press hardening of boron alloy steel. In case of novel hot formed components with tailored properties, different heating cycles needed to be applied for different zones, in which varying microstructure characteristics were generated. Mechanical properties of these parts were thus precisely controlled by the microstructure constituents. In this work, stress-strain behaviors of a boron alloy steel undergoing different heat treatment conditions with respect to that modified hot stamping procedure were predicted. Firstly, boron alloy steel sheet specimens were heated up to the austenitization temperature. Afterwards, they were abruptly cooled down to the bainitic temperature range, held for different holding times and finally cooled to room temperature. The microstructures obtained from each condition were characterized by optical microscope (OM) using color tint etching. The stress-strain responses of all generated microstructures were determined by tensile test. By the modeling, flow curves of the individual single phases were described taking into account a dislocation theory based model and their chemical composition. Subsequently, effective flow curves of the heat treated boron alloy steels were calculated by means of the isostrain and non-isostrain method and were finally compared with the experimentally determined curves.

Abstract: In the design of metalworking technologies, one of the most important amount is the flow stress of the material. A few experimental method can be used to measure it. The most commonly used tests to determine the flow curve of materials include upsetting of cylindrical or prismatic specimens, tension or torsion tests. In our work, the determination method of flow curve were investigated based on the principle of virtual power with cold working conditions. The experimental method, cylindrical upsetting, was executed on the Gleeble 3800 thermo-mechanical simulator. The goal was to determine reliable flow curve for large plastic strain. The results showed that reliable flow stress values were obtainable in equivalent plastic strain range of 0 to 0.7 by continuous cylindrical upsetting.

Abstract: The present investigation deals with the development of a methodology to predict the flow behaviour of the ZM21 magnesium alloy in given intervals of temperature and strain rate by FEM simulation of torsion testing. Equations based on the hyperbolic sine of flow stress and on the multiple linear regression were proposed and implemented into the finite element code. The flow curve shapes obtained by simulation were compared with experimental ones that were not used in the building phase of the equations. It was found that the simulation of torsion tests allows, under given conditions of temperature, strain rate and deformation levels, to obtain flow curve shapes very similar to those obtained by experiments under conditions not included in the building of the models.

Abstract: In the rapid new automobile development, the use of simulation technology is highly demanded due to shorter time to market and fashionable product styling that go beyond the rule-of-thumb in the manufacturing technology. In stamping simulation, the expected predictions rest with the part formability, spring back, blank optimization, and other vehicle integration works. These predictions are conducted concurrently during detailed product design, and intensive product validation is performed based on such predictions. In current work, it has established the experimental mechanical properties and flow curve data for thin galvanized sheet metal. Furthermore, the true prediction of part formability is investigated with established data and standard material database embedded in commercial simulation software. The tensile experiments were carried out on a uniaxial hydraulic tensile test machine with sheet metal specimen and in accordance to ASTM requirements. Three different sheet metal specimens were prepared from the longitudinal, transverse and 45⁰ degrees from the rolling direction. From experimental works and formulation, the mechanical properties, anisotropy and flow curve had been obtained. Further improvement in the embedded material database increases the prediction accuracy of FEM analysis for Body-in-White structure and crash performance.

Abstract: The conventional clinching of steels is currently limited to tensile strength less than 800 N/mm2 and to elongation at fracture more than 14 %. To realise the clinching of high-strength steels, the sheet can be heated locally at the joint, to improve ductility. Thereby the material characteristics outside the joint should be maintained. This could be achieved by means of short-time laser heating. The short-time tempering behaviour of press hardened steel 22MnB5 has been analysed. The mechanical properties during a short-time heat treatment were investigated by thermo-mechanical analysis in a deformation dilatometer. Thereby laser-assisted clinching shall be established and an efficient form-closed and force-closed connection shall be produced. As a result, the press hardened steel 22MnB5 could be clinched by laser assistance for the very first time.

Abstract: Cooling of age-hardening Al-alloys after solution annealing is a critical step with respect to distortion and residual stresses. In order to predict their extent by simulation models, the mechanical behaviour must be known in a wide range of conditions and compositions. Therefore, experimental data is needed both for calibration and validation of the mechanical model. It is known for Al-Mg-Si alloys that supersaturation of the solid solution leads to a significant increase of strength during cooling. In order to understand the influence of single alloying elements on the strengthening effect, the mechanical properties of different binary alloys are investigated experimentally. The precipitation behaviour during cooling was investigated by Differential Scanning Calorimetry in a wide cooling rate range. A methodology to determine the degree of supersaturation of the solid solution based on the calorimetric results is presented. This approach is compared to atom probe tomography data. The mechanical behaviour of the alloys after various heat treatments was analysed by mechanical tests performed in a quenching and deformation dilatometer. Flow curves with high resolution at small strains (< 3 %) were measured at different temperatures. The results of the different experimental techniques are discussed in comparison and with respect to their testing limitations.

Abstract: The machining of titanium alloys is challenging in every aspect. In order to avoid waste material by cutting processes and to improve mechanical properties, forming processes offer many advantages but harbor also challenges. To face these challenges, especially techniques like isothermal forging are promising methods. Isothermal forging is an appropriate process for achieving a microstructure with excellent properties for high performance applications in aviation technology and turbine construction. One of the main challenges in this special process is the determination of a tool material with a high temperature resistance as well as a high resistance against the work load of forging processes. Given their high hardness, temperature resistance and wear resistance, technical ceramics feature properties classifying them as generally suitable for this application. This article deals with the complete design of an isothermal forging process with ceramic tool material for titanium forming. The material characterization of the forming material by flow curve determination is performed to receive data for FE analyses. Afterwards, a ceramic tool system for isothermal forging is designed and manufactured. The tests show that especially the brittleness of technical ceramics restricts their application as tool material for isothermal titanium forming. Additional investigations on isothermal forging using carbide metal as tool material show the benefit of isothermal titanium forging. The results of metallographic analyses are given.