Numerical analysis of hot deep drawing of din 27MNCRB5 steel sheets under controlled stretching

Hot stamping has been widely studied and increasingly applied in the automotive industry. This process is characterized by its ability to stamp high strength steels, yielding products with high mechanical strength, thus reducing the weight of stamped components and therefore the vehicles weight. It also demands less energy because steel sheets are heated by induction, more efficient than electric furnaces. With controlled stretching it is possible to manufacture thinner stamped parts with high mechanical strength, therefore it is necessary to know the formability limits to prevent failure and achieve the largest possible thickness reduction. In this work the hot formability of DIN 27MnCrB5 steel sheets under stretching conditions was evaluated by numerical simulation with the finite element software Forge2008. The numerical results were compared to experimental results. Initially hot tensile tests were simulated to define the strain rate in different regions of the sample and to evaluate the deformation at fracture. For tests at 700, 800 and 900ºC it was found that the strain rates vary from 0.01 to 0.5 s-1. Experimental tensile tests were also carried out with the same conditions as simulated. Both simulation and experiments presented very similar results for the ultimate tensile strength, and therefore it was possible to assume the experimental fracture strain as a consistent input for the numerical models. With the results of the tensile tests, hot Nakazima tests were simulated to evaluate the highest dome which could be formed without failure risks caused by sheet thickness thinning. The simulation results were validated by experimental tests, and as a result, a new numerical strategy was elaborated to define the hot formability based on the plastic instability and necking localization as a function of the stamping temperature and blank dimensions

Lead extrusion analysis by finite volume method

Computational numerical simulation is nowadays largely applied in the design and analysis of metal forming process. Extrusion of metals is one main forming process largely applied in the manufacturing of metallic products or parts. Historically, the Finite Element Method has been applied for decades in metal extrusion analysis [4]. However, recently in the academy, there is a trend to use Finite Volume Method: literature suggests that metal flow by extrusion can be analyzed by the flow formulation [1, 2]. Thus, metal flow can be modelled such us an incompressible viscous fluid [2]. This hypothesis can be assumed because extrusion process is an isochoric process. The MacCormack Method is commonly used to simulate compressible fluid flow by the finite volume method [3]. However, metal extrusion and incompressible fluid flow do not present state equations for the evolution of pressure, and therefore, a velocity-pressure coupling method is necessary to obtain a consistent velocity and pressure fields [3]. Present work proposes a new numerical scheme to obtain information about metal flow in the extrusion process, in steady state. The governing equations were discretized by Finite Volume Method, using the Explicit MacCormack Method to structured and collocated mesh. The SIMPLE Method was applied to attain pressure-velocity coupling [3]. These new numerical scheme was applied to forward extrusion process of lead. The incompressible metal extrusion velocity fields achieved faster convergence and a good agreement with analytical and experimental results obtained from literature. The MacCormack Method applied for metals produced consistent results without the need of artificial viscosity as employed by the compressible flow simulation approaches. Furthermore, the present numerical results also suggest that MacCormack Method and SIMPLE can be applied in the solution of metal forming processes besides the traditional application for compressible fluid flow

Aluminium extrusion analysis by the finite volume method

Present work proposes a novel numerical scheme to calculate stress and velocity fields of metal flow in axisymmetric extrusion process in steady state. Extrusion of aluminium is one main metal forming process largely applied in manufacturing bars and products with complex cross section shape. The upper-bound, slab, slip-line methods and more recently the numerical methods such as the Finite Element Method have been commonly applied in aluminium extrusion analysis. However, recently in the academy, the Finite Volume Method has been developed for metal flow analysis: literature suggests that extrusion of metals can be modelled by the flow formulation. Hence, metal flow can be mathematically modelled such us an incompressible non linear viscous fluid, owing to volume constancy and varying viscosity in metal forming. The governing equations were discretized by the Finite Volume Method, using the Explicit MacCormack Method in structured and collocated mesh. The MacCormack Method is commonly used to simulate compressible fluid flow by the finite volume method. However, metal plastic flow and incompressible fluid flow do not present state equations for the evolution of pressure, and therefore, a velocity-pressure coupling method is necessary to obtain a consistent velocity and pressure fields. The SIMPLE Method was applied to attain pressure-velocity coupling. This new numerical scheme was applied to forward hot extrusion process of an aluminium alloy. The metal extrusion velocity fields achieved fast convergence and a good agreement with experimental results. The MacCormack Method applied to metal extrusion produced consistent results without the need of artificial viscosity as employed by the compressible flow simulation approaches. Therefore, present numerical results also suggest that MacCormack method together with SIMPLE method can be applied in the solution of metal forming processes in addition to the traditional application for compressible fluid flow

Numerical simulation of multi-directional hot forging for the reduction of forging defects

Hot forging is a metal forming process widely used in the industry. Among the many advantages are the possibility of severe plastic deformation and the improvement of mechanical properties, leading to the continued development of forging for industrial applications. The conventional hot forging of complex geometry components is performed in several steps, what is favorable to initiate, or propagate defects formed in the early steps due to the deformation path. In order to obtain products in a single processing step, this research aimed the development of an innovative multi-directional forging process. The finite element method was used to simulate the manufacturing of a 38MnSiVS5 steel connecting rod to preview the distributions of temperature, equivalent strain and von Mises stress in the forged product, as well as the formation of defects. Billets with the same volume and different lengths and widths were simulated to achieve the best material flow, which avoids fold and other forging defects, and leads to the complete flashless filling of the die. The simulation results made possible to know the proper billet geometry and the best friction condition for the proposed process

Genetic mechanisms of critical illness in COVID-19.

Host-mediated lung inflammation is present1, and drives mortality2, in the critical illness caused by coronavirus disease 2019 (COVID-19). Host genetic variants associated with critical illness may identify mechanistic targets for therapeutic development3. Here we report the results of the GenOMICC (Genetics Of Mortality In Critical Care) genome-wide association study in 2,244 critically ill patients with COVID-19 from 208 UK intensive care units. We have identified and replicated the following new genome-wide significant associations: on chromosome 12q24.13 (rs10735079, P = 1.65 × 10-8) in a gene cluster that encodes antiviral restriction enzyme activators (OAS1, OAS2 and OAS3); on chromosome 19p13.2 (rs74956615, P = 2.3 × 10-8) near the gene that encodes tyrosine kinase 2 (TYK2); on chromosome 19p13.3 (rs2109069, P = 3.98 ×  10-12) within the gene that encodes dipeptidyl peptidase 9 (DPP9); and on chromosome 21q22.1 (rs2236757, P = 4.99 × 10-8) in the interferon receptor gene IFNAR2. We identified potential targets for repurposing of licensed medications: using Mendelian randomization, we found evidence that low expression of IFNAR2, or high expression of TYK2, are associated with life-threatening disease; and transcriptome-wide association in lung tissue revealed that high expression of the monocyte-macrophage chemotactic receptor CCR2 is associated with severe COVID-19. Our results identify robust genetic signals relating to key host antiviral defence mechanisms and mediators of inflammatory organ damage in COVID-19. Both mechanisms may be amenable to targeted treatment with existing drugs. However, large-scale randomized clinical trials will be essential before any change to clinical practice

Analysis Of The Lubrication Regimes In The Wiredrawing Of Steel Aisi 304l

The proper lubrication in wiredrawing applications strongly influences frictional conditions, surface finish and tooling wear. This work presents a study of lubrication in a wiredrawing tribe-system with high speeds. The results of model analyses show it is possible to previously define the experimental conditions to obtain hydrodynamic lubrication.374

Aluminium extrusion analysis by the finite volume method

Present work proposes a novel numerical scheme to calculate stress and velocity fields of metal flow in axisymmetric extrusion process in steady state. Extrusion of aluminium is one main metal forming process largely applied in manufacturing bars and products with complex cross section shape. The upper-bound, slab, slip-line methods and more recently the numerical methods such as the Finite Element Method have been commonly applied in aluminium extrusion analysis. However, recently in the academy, the Finite Volume Method has been developed for metal flow analysis: literature suggests that extrusion of metals can be modelled by the flow formulation. Hence, metal flow can be mathematically modelled such us an incompressible non linear viscous fluid, owing to volume constancy and varying viscosity in metal forming. The governing equations were discretized by the Finite Volume Method, using the Explicit MacCormack Method in structured and collocated mesh. The MacCormack Method is commonly used to simulate compressible fluid flow by the finite volume method. However, metal plastic flow and incompressible fluid flow do not present state equations for the evolution of pressure, and therefore, a velocity-pressure coupling method is necessary to obtain a consistent velocity and pressure fields. The SIMPLE Method was applied to attain pressure-velocity coupling. This new numerical scheme was applied to forward hot extrusion process of an aluminium alloy. The metal extrusion velocity fields achieved fast convergence and a good agreement with experimental results. The MacCormack Method applied to metal extrusion produced consistent results without the need of artificial viscosity as employed by the compressible flow simulation approaches. Therefore, present numerical results also suggest that MacCormack method together with SIMPLE method can be applied in the solution of metal forming processes in addition to the traditional application for compressible fluid flow

Monitoring the integrity of massive aluminum structures using PZT transducers and the technique of impedance

Safety, performance, economy and durability are essential items to qualify materials for the manufacturing of structures used in different areas. Generally, the materials used for this purpose are formed by composites and sometimes they can present failure during the manufacturing process. Such failures can also occur during use due to fatigue and wear, causing damage often difficult to be visually detected. In these cases, the use of non destructive testing (NDT) has proven to be a good choice for assessing the materials quality. The objective of this work was the electromechanical impedance evaluation of massive aluminum structures using ultrasonic transducers to detect discontinuities in the material. The tests have been done using an impedance analyzer (Agilent 4294A), an ultrasound transducer (1.6 MHz of central frequency), two types of PZT ceramics (0.267 mm and 1 mm thickness) and four aluminum samples (250 x 50 x 50 mm) with the transducer placed at three different regions. One sample was kept intact (reference) and the others were drilled in three positions with different sizes of holes (5 mm. 8 mm and 11 mm). The electromechanical impedance was recorded for each sample. The root mean square deviation index (RMSD) between the impedance magnitude of the reference and damaged samples was calculated and it was observed an increase in the RMSD due to the increase of the diameter of the holes (failures) in the samples completely drilled. The results show that the proposed methodology is suitable for monitoring the integrity of aluminum samples. The technique may be evaluated in characterizing other materials to be used in the construction of prostheses and orthoses9437Conference on Structural Health Monitoring and Inspection of Advanced Materials, Aerospace, and Civil Infrastructur