Com a evolução dos processos de fabricação, aumenta o emprego de topografias engenheiradas com o objetivo de aumentar o desempenho dessas superfícies sob vários aspectos. Apesar do bom desempenho comprovado em algumas aplicações, existem outras em que o desempenho é questionável, como, em condições não lubrificadas e com elevadas pressões de contato. Neste cenário de dúvidas sobre a utilização de superfícies engenheiradas, o presente trabalho objetiva contribuir com as discussões por meio de um estudo do efeito de topografias anisotrópicas na transferência de material e resistência ao movimento em condições de deslizamento a seco com deformação plástica micro e macroscópica. O método utilizado contempla ensaios tribológicos que consistem, basicamente, em deslizar um material sobre superfícies engenheiradas de outro material com maior dureza, em duas condições de deformação plástica: i/ localizada no pico das asperezas em contato (ensaio pino-sobre-disco) e ii/ volumétrica (ensaio de compressão do anel). Os resultados permitiram concluir que os mecanismos de desgaste podem ser reproduzidos nos dois ensaios. Com deformação plástica microscópica (pino-sobre-disco) constatou-se que: i/ os vales e cavidades da topografia atuam de forma a evitar o contato das partículas de desgaste com o corpo em deslizamento; e ii/ os maiores valores do coeficiente de atrito foram obtidos com a superfície com maior quantidade de cavidades, a mesma condição topográfica que apresentou maior área com transferência de material. Com deformações plásticas macroscópicas (ensaio de compressão do anel) constatou-se que os vales da topografia da ferramenta atuaram como bloqueios para o deslizamento do anel conformado, o que resultou num aumento do coeficiente de atrito e redução da transferência de material. / The evolution of manufacturing progresses increases the use of engineered surfaces, seeking the improvement of the overall performance of these surfaces. Despite the enhanced performance under some circumstances, uncertainties still exist in conditions such as unlubricated and high contact pressure conditions. This work aims contributing to these discussions by studding the effect of anisotropic topographies on the material transfer and resistance to movement under dry sliding conditions including micro and macroscopic plastic deformation. The method consisted of tribological tests by sliding a material against engineered surfaces of higher hardness. Tests were conducted under two plastic deformation conditions: i/ localized on surface asperities contact (pin-on-disc test) and ii/ volumetric (ring test). Results allowed concluding that wear mechanisms can be reproduced on both tests. Under microscopic plastic deformation (pin-on-disc test) it was possible to verify that: i/ grooves and cavities have contributed to avoid the contact between wear debris and sliding body; and ii/ the higher friction coefficient was obtained when testing the surface with high amount of cavities, a condition that presented the larger area of material transfer. Under macroscopic deformation (ring test), grooves from tool topography played the role of blocking the ring material sliding, increasing friction coefficient and decreasing material transfer.

Never before has the car industry been as challenging, interesting, and demanding as it is today. New and advanced techniques are being continuously introduced, which has led to increasing competition in an almost ever-expanding car market. As the pace and complexity heightens in the car market, manufacturing processes must advance at an equal speed. An important manufacturing process within the automotive industry, and the focus of this thesis, is sheet metal forming (SMF). Sheet metal forming is used to create door panels, structural beams, and trunk lids, among other parts, by forming sheets of metal in press lines with stamping dies. The SMF process has been simulated for the past couple of decades with finite element (FE) simulations, whereby one can predict factors such as shape, strains, thickness, springback, risk of failure, and wrinkles. A factor that most SMF simulations do not currently include is the die and press elasticity. This factor is handled manually during the die tryout phase, which is often long and expensive. The importance of accurately representing press and die elasticity in SMF simulations is the focus of this research project. The research objective is to achieve virtual tryout and improved production support through SMF simulations that consider elastic die and press deformations. Loading a die with production forces and including the deformations in SMF simulations achieves a reliable result. It is impossible to achieve accurate simulation results without including the die deformations. This thesis also describes numerical methods for optimizing and compensating tool surfaces against press and die deformations. In order for these compensations to be valid, it is imperative to accurately represent dies and presses. A method of measuring and inverse modeling the elasticity of a press table has been developed and is based on digital image correlation (DIC) measurements and structural optimization with FE software. Optimization, structural analysis, and SMF simulations together with experimental measurements have immense potential to improve simulation results and significantly reduce the lead time of stamping dies. Last but not least, improved production support and die design are other areas that can benefit from these tools. / Aldrig tidigare har bilindustrin varit så utmanande, intressant och spännande som idag. Ny och avancerad teknik introduceras i en allt snabbare takt vilket leder till ständigt ökande konkurrens på en, nästan ständigt, ökande bilmarknad. Den ständigt ökande komplexiteten ställer även krav på tillverkningsprocesserna. En viktig process, som denna licentiatuppsats fokuserar på, är pressning av plåt. Tillverkningstekniken används för att forma plåtar till dörrpaneler, strukturbalkar, motorhuvar, etc. Plåtar formas med hjälp av pressverktyg monterade i plåtformningspressar. Plåtformningsprocessen simuleras sedan ett par decennium tillbaka med Finita Element (FE) simuleringar. Man kan på så sätt prediktera form, töjningar, tjocklek, återfjädring, rynkor, risk för försträckning och sprickor m.m. En faktor som för tillfället inte inkluderas i näst intill alla plåtformningssimuleringar är elastiska press- och verktygsdeformationer. Detta hanteras istället manuellt under, den oftast långa och dyra, inprovningsfasen. Detta projekt har visat på vikten av att representera press och verktygsdeformationer i plåtformningssimuleringar. Detta demonstreras genom en analys av ett verkligt pressverktyg som belastas med produktionskrafter. Det är inte möjligt att uppnå bra simuleringsresultat utan att inkludera verktygsdeformationer i simuleringsmodellen. Uppsatsen beskriver även numeriska metoder för att optimera och kompensera verktygsytor mot press och verktygsdeformationer. För att dessa kompenseringar ska stämma är det viktigt att man representerar både verktyg och press på ett korrekt sätt. Förslag på en metod för att mäta och inversmodellera pressdeformationer har utvecklats, metoden är baserad på mätningar med DIC-systemet ARAMIS och optimering i FE-mjukvaror. Optimering, strukturanalys, och plåtformningsanalys tillsammans med experimentella mätningar har en stor potential att förbättra plåtformningssimuleringar samt reducera ledtiden för pressverktyg. Sist men inte minst, andra positiva effekter är en enklare och smidigare konstruktionsprocess och förbättrad produktionssupport.

L’objectif ultime de ce travail de thèse est d’évaluer la possibilité de valider et d’optimiser un processus de fabrication en utilisant la simulation numérique en tenant compte des incertitudes irréductibles sur le procédé, les matériaux et la géométrie du produit fabriqué. La prise en compte des incertitudes nécessite de quantifier les effets des variations des paramètres du modèle sur les sorties de celui-ci, en propageant ces variations via la simulation numérique pour évaluer leurs effets sur les sorties. Dans ce travail nous avons proposé une procédure pour déterminer le seuil de sensibilité du modèle numérique afin de construire des plans d’expériences numériques cohérents avec ce seuil. Nous avons également montré que, compte tenu des incertitudes sur les matériaux et la géométrie du produit, il est possible d’optimiser certains paramètres du procédé pour contrôler les effets des incertitudes sur les variations dimensionnelles et morphologiques du produit. Pour cela, nous avons proposé une procédure d’optimisation basée sur un algorithme NSGA-II et une méta-modélisation du procédé. L’application à l’emboutissage d’une tôle en U, retour élastique inclus, montre qu’il s’agit d’un problème de conception robuste pour lequel nous obtenons l’ensemble des compromis entre l’écart à la moyenne et l’écart type d’une fonction « performance » du procédé correctement choisie. Finalement l’analyse de ces résultats nous permet de quantifier le lien entre la notion de robustesse d’une solution optimisée du procédé et les critères de mesure de la qualité du produit / The ultimate objective of this thesis is to evaluate the possibility to validate and optimize a manufacturing process using numerical simulation and taking into account the irreducible uncertainties in the process, materials and geometry of manufactured product. Taking into account the uncertainties requires quantifying the effects of variations of model parameters on the outputs, by propagating these variations via computer simulation to assess their effects on the outputs. In this work, we have proposed a procedure to determine the sensitivity threshold of the numerical model to build numerical Design of Experiments consistent with this threshold. We have also shown that, given the uncertainties in the materials and the geometry of the product, it is possible to optimize certain process parameters to control the effects of uncertainties on the dimensional and morphological variations of the product. For this, we have proposed an optimization procedure based on NSGA-II algorithm and a meta-modeling of the process. The application for deep drawing of a U-shaped sheet metal part, springback included shows that it is a robust design problem for which we get all the compromise between the deviation from the mean and standard deviation of a "performance" depending on the process correctly chosen. Finally, the analysis of these results allows us to quantify the relationship between the notion of robustness of an optimized solution of the process and criteria for measuring the quality of the product

La simulation numérique par la méthode des éléments finis (MEF) fournit de nos jours une grande aide pour les ingénieurs dans les processus de conception d’optimisation des produits. Malgré le développement croissant des ressources de calcul, la fiabilité et l’efficacité des simulations numériques par la MEF restent à améliorer. Ce travail de thèse consiste à développer une famille d’éléments solide-coque (SHB) pour la modélisation tridimensionnelle des structures minces. Cette famille d’éléments SHB est basée sur une formulation tridimensionnelle en grands déplacements et rotations. La technique dite “d’intégration réduite dans le plan”, en utilisant un nombre arbitraire de points d’intégration dans la direction de l’épaisseur, permet la modélisation des structures minces avec une seule couche d'éléments. Dans ce travail de thèse, deux éléments linéaires SHB prismatique et hexaédrique, ainsi que leurs contreparties quadratiques, ont été implantés dans le code par éléments finis ABAQUS pour l’analyse quasi-statique et dynamique des structures minces. La performance de ces éléments a été validée à travers une série de cas tests académiques, ainsi que sur des problèmes complexes de type impact/crash et des procédés de mise en forme de tôles minces. L'ensemble des résultats numériques obtenus révèle que les éléments SHB représentent une alternative intéressante aux éléments coques et solides traditionnels pour la modélisation tridimensionnelle des structures minces. / Nowadays, the finite element (FE) simulation provides great assistance to engineers in the design of products and optimization of manufacturing processes. Despite the growing development of computational resources, reliability and efficiency of the FE simulations remain the most important features. The current work contributes to the development of a family of assumed strain based solid-shell elements (SHB), for the modeling of 3D thin structures. Based on reduced integration and special treatments to eliminate locking effects and to control spurious zero-energy modes, the SHB solid‒shell elements are capable of modeling most thin 3D structural problems with only a single element layer, while describing accurately the various through-thickness phenomena. In the current contribution, a family of prismatic and hexahedral SHB elements with their linear and quadratic versions have been implemented into ABAQUS using both standard/quasi-static and explicit/dynamic solvers. The performance of the SHB elements is evaluated via a series of popular benchmarks as well as with impact/crash and sheet metal forming processes. All numerical results reveal that the SHB elements represent an interesting alternative to traditional shell and solid elements for the 3D modeling of thin structural problems.

Avec l'avancé des méthodes numériques, de nouvelles méthodes dites « sans maillage » sont apparues pour remédier à certaines limitations de la méthode des éléments finis. Ces méthodes ont la particularité de n’employer aucun maillage prédéfini : elles utilisent un ensemble de nœuds dispersés dans le domaine considéré et sur ses frontières. L’objectif de cette étude est de montrer l’intérêt de l’application des méthodes sans maillage basées sur les fonctions de base radiale pour la simulation des procédés de mise en forme en général et de poinçonnage rapide en particulier. Une attention particulière sera portée sur la méthode RPIM qui offre l’avantage de proposer une interpolation nodale. La démarche proposée dans ce document consiste: à rappeler succinctement les principes essentiels des méthodes sans maillage en précisant leurs avantages par rapport aux méthodes classiques, à présenter et à mettre en œuvre la technique numérique de la méthode sans maillage RPIM avec un calibrage des paramètres caractéristiques, et enfin, à traiter des exemples numériques de procédés de mise en forme avec amorçage et propagation de fissure qui confirmeront ces avantages. / In recent years, new methods named Meshfree methods have been developed to surmount limitations of the finite element method. The main characteristic of these methods is to not employ any pre-defined mesh: they use a set of nodes scattered within the problem domain as well as sets of nodes scattered on the boundaries of the domain. A particular attention is paid to the RPIM method, which proposes a nodal interpolation. The followed steps are: a presentation of « Meshfree methods » and their advantages compared to the traditional methods, an introduction to the meshfree RPIM method with a calibration of its associated parameters, and finally, a discussion on results obtained with the RPIM in forming processes exhibiting initiation and propagation of a crack showing the interest of the approach.

Drückwalzen als inkrementelles Umformverfahren ist aufgrund seiner Verfahrenscharakteristik mit sehr hohen Rechenzeiten bei der Finite-Elemente-Methode (FEM) verbunden. Die Modelle ModIni und FloSim sind zwei analytisch-elementare Ansätze, um dieser Prämisse entgegenzuwirken. Das für ModIni entwickelte Geometriemodell wird in der vorliegenden Arbeit weiterentwickelt, so dass eine werkstoffunabhängige Berechnung der Staugeometrie ermöglicht wird und ein deutlich größeres Anwendungsspektrum der Methode bereitsteht. Die Simulationsmethode FloSim basiert auf dem oberen Schrankenverfahren und ermöglicht somit eine Berechnung von Zylinderdrückwalzprozessen innerhalb weniger Minuten. Für die Optimierung der Methode FloSim wurden in der vorliegenden Arbeit die analytischen Grundlagen für die Berechnung der Bauteillänge sowie der Umformzonentemperatur während des Prozesses erarbeitet. Weiterhin wurde auf Basis von numerisch realisierten Parameteranalysen ein Ansatz für die analytische Berechnung des Vergleichsumformgrades von Drückwalzprozessen entwickelt. Diese drei Ansätze, zu Bauteillänge, Temperatur und Umformgrad wurden in die Simulationssoftware FloSim integriert und führen zu einer deutlichen Genauigkeitssteigerung der Methode. / Flow Forming as incremental forming process is connected with extreme long computation times for Finite-Element-Analyses. ModIni and FloSim are two analytical/elementary models to antagonize this situation. The geometry model, which was developed for ModIni, is improved within the presented work. The improvement enables the material independent computation of the pile-up geometry and permits a wider application scope of ModIni. The simulation method FloSim is based on the upper bound method, which enables the computation of cylindrical Flow Forming processes within minutes. For the optimization of the method FloSim, the basics for the analytical computation of the workpiece length during the process and the computation of the forming zone temperature were developed within this work. Fur-thermore, an analytical approach for the computation of the equivalent plastic strain of cylindrical Flow Forming processes was developed based on numerical parameter analyses. This tree approaches for computing the workpiece length, the temperature and the equivalent plastic strain were integrated in FloSim and lead to an increased accuracy.

No description available.

The challenges of weight reduction and good strength in automotive industry have drawn considerable interest in thixocasting technologies. Joining of such components with conventional fusion welding creates voids, hot cracking, distortion in shape, and more importantly evolution of dendritic microstructure that ultimately would lead to inferior mechanical properties of the weld region. Thus, the purpose of making thixocast component is lost. The friction welding which is a solid state joining process can avoid defects associated with melting and solidification in a typical fusion weld and can be a promising alternative. This process produces a weld under compressive force at the contact of workpieces rotating or moving relative to one another to produce heat and plastically displacing material from the faying surfaces. Research on semisolid processing has its origin in the early 1970s. However, from the literature survey on semisolid processing it is clear that, till date, not much work has been done in field of joining of semisolid processed components. In the area of solid state welding, in particular, it is not at all explored. In view of this, the present work is focused on exploration of joining of Thixocast A356 Aluminium alloy component by friction welding and comparison of its performance with friction weld of conventionally cast sample of the same alloy. The study is carried out experimentally as well as numerically. Moreover, the material behaviour of thixocast component at elevated temperature in solid state is also described with the help of processing maps and constitutive modelling. The hot workability of thixocast and conventionally cast A356 alloy is evaluated with the help of processing maps developed on the basis of the dynamic materials model approach using the flow stress data obtained from the isothermal compression test in wide range of temperature (300-500℃) and strain rates (0.001s-1-10s-1). The domains of the processing map are interpreted in terms of the associated microstructural mechanism. On comparing the flow stress at elevated temperature of thixocast and conventionally cast A356 alloy samples, it is observed that the flow stress of the latter showed higher value at different strain level, temperature and strain rates. This indicates that the flow property of the thixocast alloy sample is better than that of the conventionally cast one (i.e. response to plastic flow is better for the former); while at room temperature thixocast sample has higher strength. Moreover to investigate the general nature of the influence of strain, strain rate and temperature on the compressive deformation characteristics of thixocast A356 and conventionally cast A356 aluminium alloy, a comprehensive model describing the relationship of the flow stress, strain rate and temperature of the alloys at elevated temperatures is proposed by hyperbolic-sine Arrhenius-type equation and Johnson-Cook model. The validity of descriptive results based on the proposed constitutive equation is also investigated and a comparison between two constitutive models is also made. In order to numerically model the friction welding process of a thixocast A356 aluminium alloy and conventionally cast alloy of same material using a finite element method (FEM), temperature dependent physical properties, mechanical properties as well as viscoplastic constitutive equations were used in the model. A two- dimensional axisymmetric finite element model has been developed. The modelling is based on a coupled thermomechanical approach. First, a nonlinear, transient two-dimensional heat transfer model is developed to determine the temperature fields. Later, the temperature fields are used as input for a nonlinear, two-dimensional structural model in order to predict the distortions and von Mises stress. The finite element models are parametrically built using APDL (ANSYS Parametric Design Language) provided by ANSYS. The validation of the model is carried out by comparing with the experiment. Once validated, the thermomechanical model was used to perform parametric studies in order to investigate effects of various process parameters on temperature and stress distribution in the workpieces. This helps in deciding the range of parameters for friction welding experiments in order to get good weld. Both thixocast and conventionally cast samples exhibited similar temperature distribution during the friction welding process, because of identical thermophysical properties. The magnitude of von Mises stress distribution during friction welding of thixocast A356 sample is found to be lower than that of the conventionally cast sample. It is because of their different constitutive behaviour at elevated temperature. Moreover, the developed FEM model can be successfully used to predict the residual stress at various locations for different set of parameters and geometry for friction welding of thixocast and conventionally cast A356 alloy. This helps in reducing time consuming and expensive experiments on residual stress measurement. The chosen experiments based on Taguchi L27 orthogonal array were conducted on the friction welding machine which works on the principles of continuous drive-mechanism. The experimental specimens were machined from thixocast A356 aluminium alloy connecting rods as well as conventionally cast A356 aluminium alloy ingot in the form of cylindrical bars of dimensions 85mm length and 20mm diameter. The parameters used for welding were friction pressure, rpm, forge pressure, burn-off, and upset pressure. The effects of welding parameters on performance characteristics (i.e. tensile strength and weld efficiency) were evaluated. Taguchi method was applied to investigate the influence of each parameter on strength of joints and evaluate the combination of parameters that leads to the highest weld strength. Accordingly optimum process parameters was identified which helps in achieving the tensile strength of more than parent material. The optimized process parameters for friction welding of thixocast A356 aluminium alloy are rpm = 500, friction pressure = 60, upset time = 5, upset pressure = 100 and burn off = 5. The empirical relationships were also developed to predict the tensile strength. The developed relationship can be effectively used to predict the tensile strength of welded joint with a correlation coefficient of 0.86, which indicates the strong positive relationship between predicted and experimental data. Friction welding of thixocast A356 aluminium alloy helps to achieve very fine eutectic silicon particles of the order of 0.4 at the interface due to severe plastic deformation taking place during welding. Obtaining such fine eutectic silicon particles is difficult to be achieved within few seconds of processing by any other method. The hardness variation of friction welded thixocast alloy shows higher value as compared to that of a conventionally cast sample in the heat affected zone, which indicates better weld strength of the former. This was also confirmed by the tensile strength studied and fatigue test. This indicates that weldability of cast alloys will get improved if the microstructure is modified to globular type.

Orientador: Sérgio Tonini Button / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-28T00:05:58Z (GMT). No. of bitstreams: 1 Gomes_IvanAlexandreCotrick_M.pdf: 5091688 bytes, checksum: ddbd83343728d06fb6e89b21a3a06d98 (MD5) Previous issue date: 2015 / Resumo: O processo de conformação plástica através da trefilação a frio de barras de aço tem como principal dificuldade o projeto da ferramenta. Ainda hoje, projetistas lançam mão de ábacos e tabelas colecionados ao longo do tempo através dos sucessos e insucessos experimentais. Tais informações, normalmente, ficam restritas às empresas ou aos poucos técnicos, dentro das suas bibliotecas particulares, onde, devido à dificuldade de acesso às informações práticas para projetar ferramentas e processos mais complexos, a fabricação de perfis trefilados tem perdido espaço para outros meios produtivos, por vezes, mais onerosos. Assim, este trabalho compila ábacos e tabelas presentes em projetos de ferramentas para trefilação ¿ seja através das experiências próprias, seja dos resultados herdados de outros técnicos ¿ e também, o escasso material bibliográfico sobre o assunto, organizando um banco de dados para a modelagem de um método que auxilie assertivamente as tarefas do projeto para ferramentas para trefilação a frio de barras de aço, utilizando-se de programas comerciais de computador. Cabe salientar que o sistema não é definitivo, dessa forma, o programa fonte é aberto e detalhado para que seja analisado e melhorado, sendo indicados os pontos de atenção onde devem ser inseridas ou modificadas informações, tornando o acesso amigável para aderência às particularidades do processo onde for aplicado / Abstract: The process of plastic conformation by cold drawing of steel bars has it's main difficulty in the tool design. Even today, designers have abacuses and tables built over time through the successes and failures experimental. Such collections of information, usually, are restricted to companies or few technicians within their private libraries Due to the difficulty of access to practical information to design tools and more complex processes, the manufacture of cold drawn profiles has lost ground to other, sometimes more expensive, productive means. This work compiles abacuses and tables collected in my 30 years in cold drawing tools' design - either through my own experiences, either from inherited results of the private collections of other technicians - and also, the scarce bibliography about the subject, organizing a database for modeling a method that assertively assists the project tasks for cold drawing steel bars tools, using commercial software. The system is not final, thereby the program has open source and detailed for to be analyzed and improved, being indicated the points where must be inserted - or changed - information, making friendly access to the particularities of the production process where it will be applied / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

A major issue within automotive Sheet Metal Forming (SMF) concerns ensuring desired output product quality and consistent process performance. This is fueled by complex physical phenomena, process fluctuations and complicated parameter correlations governing the dynamics of the production processes. The aim of the thesis is to provide a deeper understanding of the challenges and opportunities in this regard within automotive SMF. The research is conducted in collaboration with a global automotive manufacturer.  The research shows that systematic investigations using process simulation models allow exploration of the product-process parameter interdependencies and their influence on the output product quality. Furthermore, it is shown that incorporating in-line measured data within process simulation models enhance model prediction accuracy. In this regard, automating the data processing and model configuration tasks reduces the overall modelling effort. However, utilization of results from process simulations within a production line requires real-time computational performance. The research hence proposes the use of reduced process models derived from process simulations in combination with production data, i.e. a hybrid data- and model-based approach. Such a hybrid approach would benefit process performance by capturing the deviations present in the real process while also incorporating the enhanced process knowledge derived from process simulations. Bringing monitoring and control realms within the production process to interact synergistically would facilitate the realization of such a hybrid approach. The thesis presents a procedure for exploring the causal relationship between the product-process parameters and their influence on output product quality in addition to proposing an automated approach to process and configure in-line measured data for incorporation within process simulations. Furthermore, a framework for enhancing output product quality within automotive SMF is proposed. Based on the thesis findings, it can be concluded that in-line measured data combined with process simulations hold the potential to unveil the convoluted interplay of process parameters on the output product quality parameters. / <p>Related work:</p><p>1) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-14412</p><p>2) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-14388</p><p>3) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-18935</p>