Figure 1: Schematic representation of the rotary swaging process (Source: FELSS Group GmbH).
Robert Kahlenberg, Project start 08/2020
Al-Mg-Cu alloys (2xxx series) are well-established materials in aviation industries, due to their high strength to weight ratio in combination with a decent ductility (fatigue resistance). The main process of interest in this project is the forming of tubular parts via rotary swaging, by which high dimensional accuracy is accomplished. However, many of the process parameters used today are primarily based on experience and several gaps remain with respect to the detailed microstructural evolution during processing.
Therefore, the project focuses on the investigation and the simulation of 2024 during production, using SimpleMSE (MatCalc). Especially the influence of the deformation on precipitation kinetics as well as recrystallization phenomena and the resulting mechanical properties are key aspects.
Figure 1: Flow curve simulations at various temperatures Figure 2: Simulation of Mises stresses after a quenching process
Bernhard Viernstein, Start 01/2018
For the construction of automotive components, rather complex temperature- and deformation steps are necessary. To understand the material’s behavior, microstructural simulations are used beside experimental techniques, such as mechanical tests or microscopical characterizations. The aim of this work is to develop a physically based model, which is able to calculate internal stress responses of complex components in any material state. Therefore, strengthening mechanisms, such as solid solution strengthening, precipitation strengthening and work hardening need to be included. Compression tests at different temperatures are used to calibrate the model. Figure 1 shows exemplary flow curve simulations at various temperatures.
A new Abaqus user hardening (UHARD) subroutine is developed and used to calculate the component’s Mises stresses for any material state. Therefore, the temperature, the strain and the strain rate are the required input parameters. Figure 2 shows simulated Mises stresses after a quenching process. The simulations are experimentally verified in four chosen integration points.