Modeling of Dislocation

A physically-based dislocation theory of plasticity is derived within an extended continuum mechanical context. Thermodynamically consistent flow rules at the grain boundaries are derived. With an analytical solution of a three-phase periodic laminate, dislocation pile-up at grain boundaries and dislocation transmission through the grain boundaries are investigated. For the finite element implementations, numerically efficient approaches are introduced based on accumulated field variables

Phase-Specific Strain Hardening and Load Partitioning of Cold Rolled Duplex Stainless Steel X2CrNiN23-4

Multi-phase materials often times consist of constituents with high contrasts in phase-specific mechanical properties. Here, even after homogeneous plastic deformation phase-specific residual stresses develop that may affect the components behaviour in service. For numerical simulation of phase-specific residual stresses, knowledge of the particular phase-specific strain hardening behaviour is essential. In this study, the strain hardening of ferrite and austenite in cold rolled duplex stainless steel of type X2CrNiN23-4 is investigated. By means of X-ray diffraction, the phase-specific load partitioning and residual stress evolution are analysed for uniaxial load application in three directions within the sheets plane, taking into account the sheet metals phase specific anisotropy. In order to assess the necessity for experimental determination of anisotropic phase specific behaviour, the strain hardening parameters, derived from only one loading direction, are implemented in a mean-field approach for prediction of phase-specific stresses. A simplified simulation approach is applied that only considers macroscopic plastic anisotropy and results are compared to experimental findings. For all investigated loading directions, it was observed that austenite is the high-strength phase. This load partitioning behaviour was confirmed by the evolution of phase-specific residual stresses as a result of uniaxial elasto-plastic loading. With the simplified and fast numerical approach, satisfying results for prediction of anisotropic phase-specific (residual) stresses are obtained

Residual stresses in deep-drawn cups made of duplex stainless steel X2CrNiN23-4 – Influence of the drawing depth

Residual stress development in deep drawing processes is investigated based on cylindrical cups made of duplex stainless steel sheet. Using a two-scale approach combining finite element modelling with a mean field homogenization scheme the macro residual stresses as well as the phase-specific micro residual stresses regarding the phases ferrite and austenite are calculated for steel X2CrNiN23‑4 for various drawing depths. The simulation approach allows for the numerical efficient prediction of the macro and phase-specific micro residual stress in every integration point of the entire component. The simulation results are validated by means of X‑ray diffraction residual stress analysis applied to a deep-drawn cup manufactured using corresponding process parameters. The results clearly indicate that the fast simulation approach is well suited for the numerical prediction of residual stresses induced by deep drawing for the two-phase duplex steel; the numerical results are in good agreement with the experimental data. Regarding the investigated process, a significant influence of the drawing depth, in particular on the evolution of the residual stress distribution in drawing direction, is observed. Considering the appropriate phase-specific strain hardening, the two-scale approach is also well suited for the prediction of phase specific residual stresses on the component level

Modeling of Dislocation

A physically-based dislocation theory of plasticity is derived within an extended continuum mechanical context. Thermodynamically consistent flow rules at the grain boundaries are derived. With an analytical solution of a three-phase periodic laminate, dislocation pile-up at grain boundaries and dislocation transmission through the grain boundaries are investigated. For the finite element implementations, numerically efficient approaches are introduced based on accumulated field variables

Improvement of Sheet Metal Properties by Inducing Residual Stresses into Sheet Metal Components by Embossing and Reforming

In sheet metal forming, combination of embossing and reforming allows the mechanical properties of sheet metal materials to be specifically improved. Here, local property modification is achieved by the residual stresses induced as a result of the one-sided embossing process followed by a reforming step. The residual stresses induced in this specific way can lead to a significantly increase in the fatigue strength of processed sheet metal components. However, in order to ensure this kind of component optimization in continuous operation, the induced stresses have to be homogeneous. In this respect, the main objective of the study reported about in this paper was to identify a forming strategy, consisting of the process steps embossing and reforming, that generates preferably homogeneous residual stress distributions into sheet metal blanks. For this, numerical and experimental investigations were carried out with samples of the stainless steel (X6Cr17) having a thickness of 1.5 mm. It was found that embossing and reforming, integrated into a conventional forming process, is a novel approach to specifically induce very localized homogeneous compressive residual stresses in sheet metal materials. This eliminates the need for costly post-processing by means of surface treatment