Multi-objective design optimisation of a 3D-rail stamping process using a robust multi-objective optimisation platform (RMOP)

The paper investigates the multi-objective design optimisation of a stamping process to control the final shape and the final quality using advanced high strength steels. The design problem of the stamping process is formulated to minimise the difference between the desired shape and the final geometry obtained by numerical simulation accounting elastic springback. In addition, the final product quality is maximised by improving safety zones without wrinkling, thinning, or failure. Numerical results show that the proposed methodology improves the final product quality while reduces its springback.Peer ReviewedPostprint (published version

Efficient implicit FEM simulation of sheet metal forming

For the simulation of industrial sheet forming processes, the time discretisation is\ud one of the important factors that determine the accuracy and efficiency of the algorithm. For\ud relatively small models, the implicit time integration method is preferred, because of its inherent\ud equilibrium check. For large models, the computation time becomes prohibitively large and, in\ud practice, often explicit methods are used. In this contribution a strategy is presented that enables\ud the application of implicit finite element simulations for large scale sheet forming analysis.\ud Iterative linear equation solvers are commonly considered unsuitable for shell element models.\ud The condition number of the stiffness matrix is usually very poor and the extreme reduction\ud of CPU time that is obtained in 3D bulk simulations is not reached in sheet forming simulations.\ud Adding mass in an implicit time integration method has a beneficial effect on the condition number.\ud If mass scaling is used—like in explicit methods—iterative linear equation solvers can lead\ud to very efficient implicit time integration methods, without restriction to a critical time step and\ud with control of the equilibrium error in every increment. Time savings of a factor of 10 and more\ud can easily be reached, compared to the use of conventional direct solvers.\ud

Knowledge based cloud FE simulation of sheet metal forming processes

The use of Finite Element (FE) simulation software to adequately predict the outcome of sheet metal forming processes is crucial to enhancing the efficiency and lowering the development time of such processes, whilst reducing costs involved in trial-and-error prototyping. Recent focus on the substitution of steel components with aluminum alloy alternatives in the automotive and aerospace sectors has increased the need to simulate the forming behavior of such alloys for ever more complex component geometries. However these alloys, and in particular their high strength variants, exhibit limited formability at room temperature, and high temperature manufacturing technologies have been developed to form them. Consequently, advanced constitutive models are required to reflect the associated temperature and strain rate effects. Simulating such behavior is computationally very expensive using conventional FE simulation techniques. This paper presents a novel Knowledge Based Cloud FE (KBC-FE) simulation technique that combines advanced material and friction models with conventional FE simulations in an efficient manner thus enhancing the capability of commercial simulation software packages. The application of these methods is demonstrated through two example case studies, namely: the prediction of a material's forming limit under hot stamping conditions, and the tool life prediction under multi-cycle loading conditions

A model for the formation of the active region corona driven by magnetic flux emergence

We present the first model that couples the formation of the corona of a solar active region to a model of the emergence of a sunspot pair. This allows us to study when, where, and why active region loops form, and how they evolve. We use a 3D radiation MHD simulation of the emergence of an active region through the upper convection zone and the photosphere as a lower boundary for a 3D MHD coronal model. The latter accounts for the braiding of the magnetic fieldlines, which induces currents in the corona heating up the plasma. We synthesize the coronal emission for a direct comparison to observations. Starting with a basically field-free atmosphere we follow the filling of the corona with magnetic field and plasma. Numerous individually identifiable hot coronal loops form, and reach temperatures well above 1 MK with densities comparable to observations. The footpoints of these loops are found where small patches of magnetic flux concentrations move into the sunspots. The loop formation is triggered by an increase of upwards-directed Poynting flux at their footpoints in the photosphere. In the synthesized EUV emission these loops develop within a few minutes. The first EUV loop appears as a thin tube, then rises and expands significantly in the horizontal direction. Later, the spatially inhomogeneous heat input leads to a fragmented system of multiple loops or strands in a growing envelope.Comment: 13 pages, 10 figures, accepted to publication in A&

Cosmic-ray Acceleration at Ultrarelativistic Shock Waves: Effects of a "Realistic" Magnetic Field Structure

First-order Fermi acceleration processes at ultrarelativistic shocks are studied with Monte Carlo simulations. The accelerated particle spectra are derived by integrating the exact particle trajectories in a turbulent magnetic field near the shock. ''Realistic'' features of the field structure are included. We show that the main acceleration process at superluminal shocks is the particle compression at the shock. Formation of energetic spectral tails is possible in a limited energy range only for highly perturbed magnetic fields, with cutoffs occuring at low energies within the resonance energy range considered. These spectral features result from the anisotropic character of particle transport in the downstream magnetic field, where field compression produces effectively 2D perturbations. Because of the downstream field compression, the acceleration process is inefficient in parallel shocks for larger turbulence amplitudes, and features observed in oblique shocks are recovered. For small-amplitude turbulence, wide-energy range particle spectra are formed and modifications of the process due to the existence of long-wave perturbations are observed. In both sub- and superluminal shocks, an increase of \gamma leads to steeper spectra with lower cut-off energies. The spectra obtained for the ``realistic'' background conditions assumed here do not converge to the ``universal'' spectral index claimed in the literature. Thus the role of the first-order Fermi process in astrophysical sources hosting relativistic shocks requires serious reanalysis.Comment: submitted to Ap

Analysis and modelling of a rotary forming process for cast aluminum alloy A356

Spinning of a common aluminum automotive casting alloy A356 (Al-7Si-0.3 Mg) at elevated temperatures has been investigated experimentally with a novel industrial-scale apparatus. This has permitted the implementation of a fully coupled thermomechanical finite element model aimed at quantifying the processing history (stress, strain, strain-rate and temperature) and predicting the final geometry. The geometric predictions of this model have been compared directly to the geometry of the workpieces obtained experimentally. This study is novel in regards to both the size and shape of the component as well as the constitutive material representation employed. The model predictions are in reasonable agreement with experimental results for small deformations, but errors increase for large deformation conditions. The model has also enabled the characterization of the mechanical state which leads to a common spinning defect. Suggestions for improving the accuracy and robustness of the model to provide a predictive tool for industry are discussed