Numerical modeling of metal cutting processes using the particle finite element method (PFEM) and a physically based plasticity model

Metal cutting is one of the most common metal shaping processes. Specified geometrical and surface properties are obtained by break-up of material and removal by a cutting edge into a chip. The chip formation is associated with large strain, high strain rate and locally high temperature due to adiabatic heating which make the modeling of cutting processes difficult. Furthermore, dissipative plastic and friction work generate high local temperatures. These phenomena together with numerical complications make modeling of metal cutting difficult. Material models, which are crucial in metal cutting simulations, are usually calibrated based on data from material testing. Nevertheless, the magnitude of strain and strain rate involved in metal cutting are several orders higher than those generated from conventional material testing. Therefore, a highly desirable feature is a material model that can be extrapolated outside the calibration range. In this study a physically based plasticity model based on dislocation density and vacancy concentration is used to simulate orthogonal metal cutting of AISI 316L. The material model is implemented into an in-house Particle Finite Element Method software. Numerical simulations are in agreement with experimental results, but also with previous results obtained with the finite element method

Modelling Ultra High Pressure Compaction of Powder

The use of high pressure high temperature (HPHT) equipment varies; in mineral physics research the equipment is used for investigation of the earth’s interior and in industry it is used for commercially produced synthetic diamonds and other polycrystalline products. The common denominator for almost all high pressure systems is to use capsules where a powder material encloses the core material. Numerical analysis of the manufacturing processes with working conditions which reaches ultra high pressure (above 10 GPa) requires a constitutive model which can handle the specific behaviours of the powder from a low density to solid state. Calcium carbonate (CaCO3) is a mineral that can be used in high pressure processes and is very common in the earth core. A constitutive model for calcium carbonate applied to high pressure compaction is presented. The plastic response of powder is non-linear and described in a rate-independent cap plasticity model. The cap model has been developed to capture the behaviour of minerals in high pressure applications. The yield function consists of a failure envelope fitted to a strain-hardening cap. Experimental tests with a Bridgman anvil set-up using calcium carbonate powder discs are performed. Numerical analysis using the finite element method is done to virtually reproduce the experiments. Results from the analysis are compared to measured experimental results. The numerical analyses agree reasonably well with the experimental results

PFEM-based modeling of industrial granular flows

The potential of numerical methods for the solution and optimization of industrial granular flows problems is widely accepted by the industries of this field, the challenge being to promote effectively their industrial practice. In this paper, we attempt to make an exploratory step in this regard by using a numerical model based on continuous mechanics and on the so-called Particle Finite Element Method (PFEM). This goal is achieved by focusing two specific industrial applications in mining industry and pellet manufacturing: silo discharge and calculation of power draw in tumbling mills. Both examples are representative of variations on the granular material mechanical response—varying from a stagnant configuration to a flow condition. The silo discharge is validated using the experimental data, collected on a full-scale flat bottomed cylindrical silo. The simulation is conducted with the aim of characterizing and understanding the correlation between flow patterns and pressures for concentric discharges. In the second example, the potential of PFEM as a numerical tool to track the positions of the particles inside the drum is analyzed. Pressures and wall pressures distribution are also studied. The power draw is also computed and validated against experiments in which the power is plotted in terms of the rotational speed of the drum

Identification of fracture toughness parameters to understand the fracture resistance of advanced high strength sheet steels

The fracture toughness of four advanced high strength steel (AHSS) thin sheets is evaluated through different characterization methodologies, with the aim of identifying the most relevant toughness parameters to describe their fracture resistance. The investigated steels are: a Complex Phase steel, a Dual Phase steel, a Trip-Aided Bainitic Ferritic steel and a Quenching and Partitioning steel. Their crack initiation and propagation resistance is assessed by means of J-integral measurements, essential work of fracture tests and Kahn-type tear tests. The results obtained from the different methodologies are compared and discussed, and the influence of different parameters such as specimen geometry or notch radius is investigated. Crack initiation resistance parameters are shown to be independent of the specimen geometry and the testing method. However, significant differences are found in the crack propagation resistance values. The results show that, when there is a significant energetic contribution from necking during crack propagation, the specific essential work of fracture (we) better describes the overall fracture resistance of thin AHSS sheets than JC. In contrast, energy values obtained from tear tests overestimate the crack propagation resistance and provide a poor estimation of AHSS fracture performance. we is concluded to be the most suitable parameter to describe the global fracture behaviour of AHSS sheets and it is presented as a key property for new material design and optimization.Peer ReviewedPostprint (author's final draft

Electrophysiological features of familial amyloid polyneuropathy in endemic area

The process of deterioration of peripheral nerve function in familial amyloid polyneuropathy (FAP) with amyloidogenic transthyretin (ATTR) Val30Met has not been systematically evaluated hitherto. We performed nerve conduction studies in 69 patients with FAP with ATTR Val30Met from one of the endemic areas in Japan. Sensory conduction velocity (SCV), motor conduction velocity (MCV), the size of the compound muscle action potential (CMAP) and distal latency (DL) were measured in the ulnar and tibial nerves. SCV was evaluated using the orthodromic method with needle recording electrodes. These electrophysiological parameters were compared with clinical stage of FAP and duration of neuropathy. When subjects noted minimal neuropathic symptoms only in the feet, motor and sensory nerve function in both the hands and feet had already been disturbed. Sensory nerve action potential on the foot disappeared more rapidly than CMAP. CMAP on foot muscle rapidly decreased during the initial 2 years and completely disappeared within 10 years. The duration of illness and deterioration parameters (CMAP of the abductor digiti minimi muscle, MCV and SCV of the ulnar nerve and DL of both ulnar and tibial nerves) were linearly correlated. CMAP was the most sensitive and reliable parameter to evaluate motor nerve degeneration in FAP.</.ArticleAMYLOID-JOURNAL OF PROTEIN FOLDING DISORDERS. 18(1):10-18 (2011)journal articl

Modelling and validation of the interactions between pulp, charge and mill structure in a full- body model tumbling mill

Harshwor

Dislocation density based flow stress model applied to the PFEM simulation of orthogonal cutting processes of Ti-6Al-4V

Machining of metals is an essential operation in the manufacturing industry. Chip formation in metal cutting is associated with large plastic strains, large deformations, high strain rates and high temperatures, mainly located in the primary and in the secondary shear zones. During the last decades, there has been significant progress in numerical methods and constitutive modeling for machining operations. In this work, the Particle Finite Element Method (PFEM) together with a dislocation density (DD) constitutive model are introduced to simulate the machining of Ti-6Al-4V. The work includes a study of two constitutive models for the titanium material, the physically based plasticity DD model and the phenomenology based Johnson-Cook model. Both constitutive models were implemented into an in-house PFEM software and setup to simulate deformation behaviour of titanium Ti6Al4V during an orthogonal cutting process. Validation show that numerical and experimental results are in agreement for different cutting speeds and feeds. The dislocation density model, although it needs more thorough calibration, shows an excellent match with the results. This paper shows that the combination of PFEM together with a dislocation density constitutive model is an excellent candidate for future numerical simulations of mechanical cutting. © 2020 by the authors

Informe del Taller Regional de Estadísticas Ambientales: "Hacia el desarrollo de un conjunto básico de estadísticas ambientales", Santiago de Chile, 26 al 28 de noviembre de 2003"

The prediction of transient granular material flow is of fundamental industrial importance. The potential of using numerical methods in system design for increasing the operating efficiency of industrial processes involving granular material flow is huge. In the present study, a numerical tool for modelling dense transient granular material flow is presented and validated against experiments. The granular materials are modelled as continuous materials using two different constitutive models. The choice of constitutive models is made with the aim to predict the mechanical behaviour of a granular material during the transition from stationary to flowing and back to stationary state. The particle finite element method (PFEM) is employed as a numerical tool to simulate the transient granular material flow. Use of the PFEM enables a robust treatment of large deformations and free surfaces. The fundamental problem of collapsing rectangular columns of granular material is studied experimentally employing a novel approach for in-plane velocity measurements by digital image correlation. The proposed numerical model is used to simulate the experimentally studied column collapses. The model prediction of the in-plane velocity field during the collapse agrees well with experiments.Validerad;2021;Nivå 2;2021-01-22 (alebob);Finansiär: KIC RawMaterials (17152)</p

Effects of aspect ratio and specimen size on uniaxial failure stress of iron green bodies at high strain rates

Powder metallurgy is used for the production of a number of mechanical parts and is an essential production method. These are great advantages such as product cost effectiveness and product uniqueness. In general, however parts created by powder metallurgy have low strength because of low density. In order to increase strength as well as density, new techniques such as high-velocity-compaction (HVC) was developed and further investigation has been conducted on improvement of techniques and optimum condition using computer simulation. In this study, the effects of aspect ratio and specimen size of iron green bodies on failure strength of uniaxial compression and failure behavior were examined using a split Hopkinson pressure Bar. The diameters of specimens were 12.5 mm and 25 mm the aspect ratios (thickness/diameter) were 0.8 and 1.2