This diploma thesis deals with simulation of cross-roll straightening using computational modeling with finite element method in software ANSYS. The main goal of this thesis is to quantify the influence of inaccurate knowledge of mechanical properties on the straightening process and correct setting of machine. It also aims for comparison of hardening models and their influence on the final curvature and residual stresses in the cross section of the bar.

Die Genauigkeit der Ergebnisse einer numerischen Simulation von Umformvorgängen wird maßgeblich durch die Beschreibung des Materialverhaltens bestimmt. Neben der Auswahl eines geeigneten Stoffgesetzes zur Darstellung einer Klasse von Werkstoffen ist die Identifikation der in den Modellen enthaltenen Materialparameter zur Charakterisierung seiner besonderen Eigenschaften notwendig. In der vorliegenden Arbeit wird die Bestimmung der Materialparameter eines elastisch-plastischen Deformationsgesetzes zur Beschreibung der plastischen Anisotropie auf Basis der Fließbedingung von Hill unter Berücksichtigung großer Deformationen vorgenommen. Die Ermittlung der Parameter erfolgt durch die Lösung einer nichtlinearen Optimierungsaufgabe (Fehlerquadratminimum) basierend auf dem Vergleich von experimentell durchgeführten Eindringversuchen mit Ergebnissen der numerischen Simulation.

Confined particulate systems, particularly powder compacts, are widely used in various applications in industries such as pharmaceutical, automotive, agriculture, and energy production. Due to their extensive applications, characterization of these materials is of great importance for optimizing their performance and manufacturing processes. Modeling approaches capable of capturing the heterogeneity and complex behavior are effective at predicting the macroscopic behavior of granular systems. These modeling approaches utilize information about the microstructure evolution of these materials during compaction processes at the mesoscale (particle-scale). Using these types of modeling depend on accurate contact formulation between inter-particle contacts. The challenge comes in formulating these contact models that accurately predict force-area-deformation relationships. In this work, contact laws are presented for elastic-ideally plastic particles and plastic particles with power-law hardening under unconfined (simple compression) and confined (die and hydrostatic compaction) compression. First, material properties for a set of finite element simulations are obtained using space-filling design. The finite element simulations are used for verification and building an analytical framework of the contact radius and contact pressure which allows for efficient determination of the contact force. Semi-mechanistic contact laws are built for elastic-ideally plastic spherical particles that depend on material properties and loading configuration. Then, rigid-plastic assumption is used to modify the contact laws to consider power-law hardening effects while keeping loading configuration dependency. Finally, after building and verifying the contact laws, they are used to estimate hardening properties, contact radius evolution, and stress response of micro-crystalline cellulose particles under different loading configurations using experimental data from simple compression.