M.Ing. / During all manufacturing processes it is crucial to use certain design criteria and guidelines. Special care should be exercised when the final product of a manufacturing process is used in the automotive industry, because the failure of such a component may have tragic consequences. The failure of a bus chassis in the public transport sector is an example of a case where the failure of a product can have serious consequences. In recent years it has become common practice to use corrosion-resisting steel in the manufacture of these vehicles. The reason for this is the corrosion caused by a prolonged service life and adverse conditions such as salted road surfaces (The salt is used to melt the ice that forms on roads, particularly in European countries). These bus structures consist of tubes of varying size and geometry, and the manufacturing process of these tubes is considered in the present investigation. In a tube manufacturing process the design criteria may consist of such properties as the tube size and geometry, the thickness of the sheet that is used and the radius of the corners of the tube. Design criterion is also dependent upon the material that is used. The change in mechanical properties of the material during a manufacturing process is an important consideration during the establishment of design guidelines. The purpose of this investigation is to study the effects of particularly the cold forming manufacturing process on the mechanical properties of the material. The material used is 3CR12 corrosion resisting steel, a proprietary alloy also known as Type 1.4003, that was developed by Columbus joint venture as a cheaper alternative to stainless steels. 3CR12 is not a substitute for stainless steel but it is an alternative to treated mild steel, providing a cost-effective solution to corrosion. An experimental investigation is conducted into the forming of 40mm 3CR12 square tubes and normal plate bending of 3CR12. Various different wall thicknesses and bend radiuses are considered. A numerical investigation consisted of simulating the above-mentioned manufacturing processes using non-linear finite element analysis and then comparing its results to the experimental investigation. The experimental investigation showed that substantial work hardening occurred in the corner regions of the tube during forming. A loss of up to 70% of 3CR12's ductility may result in the corner regions. The work hardening at the inside of the tube was found to be higher than at the outside. A region of very little work hardening near the middle of the tube wall thickness was also identified (neutral axis). This neutral axis also seems to shift slightly more to the inside of the tube with thicker wall sections. The numerical analysis confirmed the experimental observations. An excellent correlation between the experimental and numerical results was achieved.

Orientador: Peterson Luiz Ferrandini / Banca: Carlos Triveño Rios / Banca: Manoel Cleber de S. Alves / Resumo: A atual exigência de qualidade de grandes peças forjadas requeridas pelo mercado nos traz a necessidade de dominar completamente cada etapa do processo de produção das mesmas. O tratamento térmico de homogeneização, processo aplicado a lingotes utilizados na fabricação de cilindros de laminação de tiras a frio, tem como objetivo homogeneizar a microestrutura bruta de solidificação que irá sofrer um processo de conformação mecânica posterior, reduzindo o nível de microssegregações nas regiões interdentriticas da estrutura do lingote. Pode-se quantificar o impacto da temperatura e do tempo deste processo pela análise da microestrutura formada a partir de um resfriamento brusco em amostras retiradas de diferentes regiões do lingote. Este trabalho foi realizado a partir de um lingote de aço do tipo A2, fundido, de comprimento ~2 m e diâmetro ~1 m, a ser forjado e utilizado na fabricação de um cilindro de laminação. Foram retiradas e analisadas amostras da estrutura bruta de solidificação e também de amostras homogeneizadas e temperadas. As amostras foram retiradas na superfície do lingote, no meio raio e na região central; foram aplicados tratamentos térmicos a 1150°C e 1200°C, por 8 h, 16 h e 24 h. Foram utilizadas microscopia ótica e eletrônica de varredura. Como esperado, a estrutura bruta de solidificação apresentou altos níveis de segregação, principalmente na região central do lingote. O tempo de homogeneização de 8 h se mostrou insuficiente a despeito da temperatura utilizada. A temperatura de 1150°C é aceitável para tratamentos de 24 h e a completa homogeneização da estrutura só foi alcançada utilizando-se tratamento a 1200°C. A estrutura bruta de solidificação apresenta uma microestrutura heterogênea, caracterizada pelo aspecto dendritico. A estrutura homogeneizada e temperada apresenta microestrutura ... (Resumo completo, clicar acesso eletronico abaixo) / Abstract: The current requirement for large forgings quality required by the market brings the demand to manage completely each stage of the manufacturing process. The homogenizing heat treatment process applied in ingots used in the manufacture of cold rolling mill rolls aims to homogenize the microstructure of raw solidification that will suffer a subsequent mechanical forming process, reducing the level of microsegregations in interdentrite regions structure of the ingot. We quantified the effect of temperature and time of the process through the analysis of the microstructure formed after a sudden cooling, in samples taken from different regions of the ingot. This task was realized applying an A2 kind of steel, cast, length ~ 2 m, diameter ~ 1 m, to be forged and used in the manufacture of a rolling Mill rolls. Samples of the raw structure solidification and the homogenizations and tempered samples were taken and analyzed .The samples were taken at the ingot surface at the middle radius and the central region; Heat treatments were applied with temperatures between 1150°C and 1200°C through 8 h, 16 h and 24 h. Optical microscopy and scanning electron microscopy were used. As expected, the raw solidification structure showed high levels of segregation, especially in the central region of the ingot. The 8 h proved to be insufficient despite the temperature used. The temperature of 1150 ° C is acceptable for treatment of 24 h and complete homogenization of the structure was only achieved by using treatment at 1200 ° C. The raw structure of solidification has a heterogeneous microstructure, characterized by dendritic appearance. The homogenized and quenched structure resulted in a microstructure composed by austenite, grades of martensite, the solidification carbides and precipitates carbides during heat treatment / Mestre

University of Macau / Faculty of Science and Technology / Department of Civil and Environmental Engineering

Cold worked magnesium powder was investigated to determine the effect of annealing on the residual strains and heat of combustion. The residual rms strains, domain size, and fault probabilities were determined by Fourier analysis of X-ray diffraction data. The heat of combustion was determined by using an adiabatic calorimeter. The results of this study revealed a definite reduction in residual rms strain (0. 0008 to 0. 0003), fault probability (0.0014 to 0. 0001%), and heat of combustion (5662 to 5445 cal/gm) with annealing. The domain size showed an increase from 1400 to 7000 A.Ball State UniversityMuncie, IN 47306

The motivation behind this study is the lack of specialized analysis regarding internal failure caused by the adiabatic shear hand (ASB) phenomenon in the cold-headed products. Its aim was to present an integrated workability study to improve and assist cold-heading (CH) multistage design procedures to replace the current design rules of thumb, as they are neither effective nor adequate in fulfilling the needs of the new developments in the rapidly expanding CH industry. / To achieve these goals, a comprehensive testing methodology and FE modeling, implemented within ABAQUS/Explicit, were established. This methodology includes an instrumented Drop Weight Compression Test (DWCT) tower equipped with a guided pocket die-set configuration capable of developing internal failure at different stages of ASBs and integrated metallographic inspection techniques. A validated FE model of the DWCT and guided pocket die-set configuration was a valuable tool in establishing the failure criteria and indicating the workability limits. / A detailed experimental and FE study for the ASB stages in the CH process was introduced to uncover the affect of different parameters controlling the failure mechanisms within the ASBs in the CH process. This study investigated the effect of the thermal, geometric and the material flow softening and hardening mechanisms affecting ASB evolution. Moreover, a detailed metallurgical and FE study of the internal ductile and Transformed Adiabatic Shear Band (TASB) failures caused by the ASB phenomenon in DWCT was conducted. / Three ductile failure criteria were introduced to predict the initiation and location of the internal ductile failure in the ASBs. One TASB failure criteria was introduced to predict the phase transformation to undesirable brittle martensite. These failure criteria were employed to establish integrated workability methodologies to indicate the objective workability limits. / Applying these workability methodologies on multistage CH FE models showed that these methodologies are an efficient tool to predict the damage levels and failure initiation locations within the cold-headed bolts. Moreover, these methodologies were successful in optimizing the die designs in order to reduce damage levels.

Made available in DSpace on 2015-09-17T15:26:33Z (GMT). No. of bitstreams: 0 Previous issue date: 2015-06-01. Added 1 bitstream(s) on 2015-09-17T15:45:30Z : No. of bitstreams: 1 000846834.pdf: 4780634 bytes, checksum: 1da2cd6d1c25c9de82cf58c75350c181 (MD5) / A atual exigência de qualidade de grandes peças forjadas requeridas pelo mercado nos traz a necessidade de dominar completamente cada etapa do processo de produção das mesmas. O tratamento térmico de homogeneização, processo aplicado a lingotes utilizados na fabricação de cilindros de laminação de tiras a frio, tem como objetivo homogeneizar a microestrutura bruta de solidificação que irá sofrer um processo de conformação mecânica posterior, reduzindo o nível de microssegregações nas regiões interdentriticas da estrutura do lingote. Pode-se quantificar o impacto da temperatura e do tempo deste processo pela análise da microestrutura formada a partir de um resfriamento brusco em amostras retiradas de diferentes regiões do lingote. Este trabalho foi realizado a partir de um lingote de aço do tipo A2, fundido, de comprimento ~2 m e diâmetro ~1 m, a ser forjado e utilizado na fabricação de um cilindro de laminação. Foram retiradas e analisadas amostras da estrutura bruta de solidificação e também de amostras homogeneizadas e temperadas. As amostras foram retiradas na superfície do lingote, no meio raio e na região central; foram aplicados tratamentos térmicos a 1150°C e 1200°C, por 8 h, 16 h e 24 h. Foram utilizadas microscopia ótica e eletrônica de varredura. Como esperado, a estrutura bruta de solidificação apresentou altos níveis de segregação, principalmente na região central do lingote. O tempo de homogeneização de 8 h se mostrou insuficiente a despeito da temperatura utilizada. A temperatura de 1150°C é aceitável para tratamentos de 24 h e a completa homogeneização da estrutura só foi alcançada utilizando-se tratamento a 1200°C. A estrutura bruta de solidificação apresenta uma microestrutura heterogênea, caracterizada pelo aspecto dendritico. A estrutura homogeneizada e temperada apresenta microestrutura ... (Resumo completo, clicar acesso eletronico abaixo) / The current requirement for large forgings quality required by the market brings the demand to manage completely each stage of the manufacturing process. The homogenizing heat treatment process applied in ingots used in the manufacture of cold rolling mill rolls aims to homogenize the microstructure of raw solidification that will suffer a subsequent mechanical forming process, reducing the level of microsegregations in interdentrite regions structure of the ingot. We quantified the effect of temperature and time of the process through the analysis of the microstructure formed after a sudden cooling, in samples taken from different regions of the ingot. This task was realized applying an A2 kind of steel, cast, length ~ 2 m, diameter ~ 1 m, to be forged and used in the manufacture of a rolling Mill rolls. Samples of the raw structure solidification and the homogenizations and tempered samples were taken and analyzed .The samples were taken at the ingot surface at the middle radius and the central region; Heat treatments were applied with temperatures between 1150°C and 1200°C through 8 h, 16 h and 24 h. Optical microscopy and scanning electron microscopy were used. As expected, the raw solidification structure showed high levels of segregation, especially in the central region of the ingot. The 8 h proved to be insufficient despite the temperature used. The temperature of 1150 ° C is acceptable for treatment of 24 h and complete homogenization of the structure was only achieved by using treatment at 1200 ° C. The raw structure of solidification has a heterogeneous microstructure, characterized by dendritic appearance. The homogenized and quenched structure resulted in a microstructure composed by austenite, grades of martensite, the solidification carbides and precipitates carbides during heat treatment

Made available in DSpace on 2014-10-09T12:52:21Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:00:50Z (GMT). No. of bitstreams: 0 / Dissertacao (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

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Made available in DSpace on 2014-10-09T12:55:39Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:05:05Z (GMT). No. of bitstreams: 0 / Dissertacao (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN-CNEN/SP