Neste trabalho foram determinadas as propriedades monotônicas e de fadiga de baixo-ciclo em chapa fina de um aço livre de intersticiais (aço IF) com adição de titânio, utilizado na indústria automobilística. Os ensaios de fadiga foram realizados sob controle de deformação com R&#949 = -1 e com o auxílio de um sistema de alinhamento de garras. O material apresenta diferentes comportamentos de fadiga nas direções transversal e longitudinal (em relação à direção de laminação). Comparação entre a curva tensão-deformação monotônica e a curva tensão-deformação cíclica mostra que os corpos de prova transversais têm endurecimento cíclico para as amplitudes de deformação estudadas. A relação deformação-vida obtida para a direção transversal é dada por &#916&#949t/2 = 0,0186(2Nf)-0,262 + 0,235(2Nf)-0,476 com ponto de transição em 2Nt = 1,4x105 reversos, não sendo possível obtê-la para a direção longitudinal devido a problemas de flambagem. Vários métodos estimativos de propriedades de fadiga a partir de propriedades monotônicas foram comparados aos resultados experimentais. Os métodos da correlação quatro pontos e inclinação universal modificada apresentando boa correlação para a região de baixo-ciclo. Análise fratográfica por microscopia eletrônica de varredura mostrou a presença de estrias de propagação do estágio II, evidenciando a alta dutilidade do material. / In the present work, the monotonic and low cycle fatigue properties of thin sheet of interstitial free steel containing titanium additions, used in the automotive industry, were investigated. Fatigue tests were conducted under deformation control (R&#949 = -1) using a grip alignment fixture. The material exhibits different fatigue behavior for the transverse and longitudinal directions (in relation to the rolling direction). A comparison between the monotonic stress-strain curve and the cyclic stress-strain curve in the transverse direction showed that the material exhibits cyclic hardening in all strain amplitudes tested. The strain-life relationship obtained for transverse direction is given by &#916&#949t/2 = 0,0186(2Nf)-0,262 + 0,235(2Nf)-0,476 with transition point in 2Nt = 1,4x105 reverses; buckling of longitudinal specimens made impossible to obtain such relationship. Several prediction methods of fatigue properties from monotonic properties were compared to the experimental results. The Four Point Correlation and the Modified Universal Slopes Methods showed a good correlation for the low cycle region. Fractographic analysis through Scanning Eletronic Microscopy showed the presence of Stage II striations, giving support to the high ductility of the material.

The aim of this master´s thesis is the design, proposal and production of a functional jig for technological testing of metal sheet by bending in the pre-production stage to the limit bend radius of the steel sheet up to a thickness of 2 mm, or in case of non-ferrous metal to a thickness of 3 mm. The required bending angle is in the range from zero to ninety degrees. The functionality of the jig will be verified by a practical testing of springing. The proposal will be supported by technological and economic calculations and technical - economic evaluation.

Globalisierung, gestiegener Konkurrenzdruck und ein effektiver Einsatz von Ressourcen zwingen die Unternehmen – nicht nur in der Automobilindustrie – zu einer permanenten Effizienzsteigerung im Entwicklungsprozess. Um schnell das optimale Design zu finden, kommen CAD- und CAE- Programme in einer frühen Entwicklungsphase des Bauteils zum Einsatz. Durch eine virtuelle Überprüfung und Verbesserung z.B. von Funktion, Gewicht und Lebensdauer können kostenintensive Prototypen und Versuche erheblich minimiert werden. In der Automobilindustrie rücken zudem akustische Eigenschaften immer mehr in den Fokus. Ein geringes Innenraumgeräusch oder der spezielle »Sound« eines Fahrzeuges sind klassenspezifische Qualitätsmerkmale, welche die Kaufentscheidung des Kunden stark beeinflussen (Zeller 2009). Bei der Konstruktion von Karosseriebauteilen muss dabei besonderes Augenmerk auf die Vermeidung von Resonanzeffekten gelegt werden. Moderne CAD-Programme – wie CATIA V5® der Fairma Dassault – bieten bereits die Möglichkeit im CAD-Workflow Bauteileigenschaften zu ermitteln. Somit verschmelzen zunehmend die Grenzen zwischen Berechnung und Konstruktion. Allerdings setzt jeder Teilbereich Erfahrung und Expertenwissen voraus, wodurch immer noch eine entsprechende Kaskadierung der Aufgaben im Entwicklungsprozess zu finden ist. Diese wird nachstehend erläutert.

CoordenaÃÃo de AperfeiÃoamento de Pessoal de NÃvel Superior / Este trabalho teve como objetivo o estudo exploratÃrio do processo MIG/MAG-DA-PI utilizando corrente alternada. Os ensaios foram executados em simples deposiÃÃo na posiÃÃo plana em chapas de aÃo baixo carbono com espessura de 3 mm utilizando arame eletrodo de 1,2 mm de diÃmetro. Foram realizados estudos sobre o nÃvel de corrente, tipo de onda aplicado em corrente alternada (CA-CP e CA-CC), a porcentagem de corrente alternada com o eletrodo na polaridade negativa (% CAEN), o sentido de deslocamento do eletrodo em relaÃÃo ao tipo de onda. Foi realizado tambÃm um estudo comparativo entre as soldagens realizadas em corrente alternada com corrente pulsada e sobre a disposiÃÃo dos eletrodos em relaÃÃo à direÃÃo de soldagem (âtandemâ e lado a lado). Foram avaliados os efeitos destes estudos nas caracterÃsticas geomÃtricas (penetraÃÃo, reforÃo e largura), na diluiÃÃo, na taxa de fusÃo do arame eletrodo, no aspecto superficial do cordÃo de solda e na microestrutura resultante na regiÃo de grÃos grossos da zona afetada pelo calor. Foi constatado que o aumento no nÃvel de corrente promove o aumento nas caracterÃsticas geomÃtricas, da diluiÃÃo e da taxa de fusÃo. A aplicaÃÃo de corrente alternada na soldagem MIG/MAG-DA-PI promoveu o aumento da taxa de fusÃo do arame, do reforÃo com a diminuiÃÃo da diluiÃÃo e da largura do cordÃo de solda. O aumento da % CAEN resultou no aumento do reforÃo, da taxa de fusÃo do arame, reduÃÃo da largura, da diluiÃÃo da solda e no refino da microestrutura. A aplicaÃÃo de corrente alternada no eletrodo anterior promoveu a reduÃÃo da diluiÃÃo com o aumento do reforÃo. Em comparaÃÃo com o uso da corrente pulsada, aplicaÃÃo de corrente alternada no processo MIG/MAG-DA-PI, para um mesmo nÃvel de corrente eficaz, resultou no aumento do reforÃo, da taxa de fusÃo do arame com a diminuiÃÃo da largura e da diluiÃÃo da solda. / The use of alternating current (or variable polarity) on the tandem GMAW process was investigated experimentally. Bead-on-plate test, in flat position, were carried out using a 1.2 mm diameter on mild steel sheet (3mm-thick). The level of welding current, waveform type applied in alternating current tandem GMAW: alternating-continuous current (AC-CC) and alternating-pulsed current (AC-PC), the percentage of alternating current in the negative polarity (% DCEN), the displacement direction of electrode applied related to waveform type. It was also carried out a comparative study between variable polarity and pulsed current in tandem GMAW and, a comparative study about the arrangement of electrodes in respect to the welding direction (tandem and side-by-side). The effects on welding geometric characteristics (penetration, reinforcement and width), weld dilution, electrode fusion rate and microstructure on coarsened grain heat affected zone (CG-HAZ) were evaluated. The experiments revealed that as current level increase, the geometrics characteristics, dilution and electrode fusion rate increased accordingly. The application of variable polarity in tandem GMAW process resulted in an increase on electrode fusion rate, reinforcement and, reduction of dilution and width of weld bead. Increasing % DCEN resulted in increase reinforcement and electrode fusion rate, reduction of dilution and width and, a refinement of microstructure. By applying variable polarity waveform on the trailing electrode, dilution is reduced and reinforcement is increased. Comparing welds made with pulsed current, the use of variable polarity in tandem GMAW process resulted in increase of reinforcement, electrode fusion rate and, reduction of width and dilution.

Devido à crescente demanda por perfis formados a frio destinados à fabricação de estruturas de aço no Brasil, aliada a desatualização da norma brasileira NB-143:1967, fez-se necessário a publicação de uma nova norma brasileira de \'Dimensionamento de Estruturas de Aço Constituídas por Perfis Formados a Frio\' a NBR14762:2001. Essa apresenta, para o dimensionamento das ligações, expressões adaptadas da norma norte-americana AISI:1996. As adaptações foram inseridas com o intuito de simplificar o cálculo e foram determinadas apenas por ajustes teóricos, faltando, portanto uma investigação mais criteriosa. Deste modo tornou-se prioritário o estudo das ligações em chapas e perfis com pequena espessura, para avaliação destas expressões propostas. Neste âmbito analisou-se neste trabalho o comportamento estrutural de ligações parafusadas em chapas e perfis formados a frio de pequena espessura, mediante análise teórica e experimental de corpos-de-prova, os quais foram definidos de maneira a se obter os diversos modos de falha, em especial a ruptura da seção líquida. Com os resultados experimentais pôde-se sugerir modificações nas expressões do coeficiente redutor da área líquida Ct, aplicado na avaliação da resistência ao estado limite de ruptura da seção líquida efetiva. Com os resultados desta pesquisa, espera-se colaborar com futuras edições da norma brasileira, fornecendo subsídios em suas futuras revisões. / The growing demand for cold-formed steel members of steel structures in Brazil, allied to the obsolescence of the brazilian NB-143:1967 standard, led to the need for a new brazilian code for the \'Design of Cold-formed Steel Structural Members\', the NBR14762:2001 standard. This new standard contains expressions adapted from the american AISI:1996 code for the design of connections. The adaptations were included with the purpose of simplifying the calculation and were determined merely for theoretical adjustments; hence, they lack a more careful investigation. It has thus become a matter of priority to study the connections in thin sheets and cold-formed members to evaluate the proposed expressions. The work reported on here therefore analyzed the structural behavior of bolted connections in thin sheets and cold-formed members based on theoretical and experimental analyses of test specimens, which were defined in order to obtain the various failure modes, particularly on sheet tearing in the net section. Based on the experimental results, suggestions are made for modifications in the expressions of the reduction coefficient of the net area Ct, applied in evaluations of the tensile strength of the effective net section. It is expected that the results of this research will contribute to future editions of the new brazilian code, supplying inputs for use in future revisions.

Devido à crescente demanda por perfis formados a frio destinados à fabricação de estruturas de aço no Brasil, aliada a desatualização da norma brasileira NB-143:1967, fez-se necessário a publicação de uma nova norma brasileira de \'Dimensionamento de Estruturas de Aço Constituídas por Perfis Formados a Frio\' a NBR14762:2001. Essa apresenta, para o dimensionamento das ligações, expressões adaptadas da norma norte-americana AISI:1996. As adaptações foram inseridas com o intuito de simplificar o cálculo e foram determinadas apenas por ajustes teóricos, faltando, portanto uma investigação mais criteriosa. Deste modo tornou-se prioritário o estudo das ligações em chapas e perfis com pequena espessura, para avaliação destas expressões propostas. Neste âmbito analisou-se neste trabalho o comportamento estrutural de ligações parafusadas em chapas e perfis formados a frio de pequena espessura, mediante análise teórica e experimental de corpos-de-prova, os quais foram definidos de maneira a se obter os diversos modos de falha, em especial a ruptura da seção líquida. Com os resultados experimentais pôde-se sugerir modificações nas expressões do coeficiente redutor da área líquida Ct, aplicado na avaliação da resistência ao estado limite de ruptura da seção líquida efetiva. Com os resultados desta pesquisa, espera-se colaborar com futuras edições da norma brasileira, fornecendo subsídios em suas futuras revisões. / The growing demand for cold-formed steel members of steel structures in Brazil, allied to the obsolescence of the brazilian NB-143:1967 standard, led to the need for a new brazilian code for the \'Design of Cold-formed Steel Structural Members\', the NBR14762:2001 standard. This new standard contains expressions adapted from the american AISI:1996 code for the design of connections. The adaptations were included with the purpose of simplifying the calculation and were determined merely for theoretical adjustments; hence, they lack a more careful investigation. It has thus become a matter of priority to study the connections in thin sheets and cold-formed members to evaluate the proposed expressions. The work reported on here therefore analyzed the structural behavior of bolted connections in thin sheets and cold-formed members based on theoretical and experimental analyses of test specimens, which were defined in order to obtain the various failure modes, particularly on sheet tearing in the net section. Based on the experimental results, suggestions are made for modifications in the expressions of the reduction coefficient of the net area Ct, applied in evaluations of the tensile strength of the effective net section. It is expected that the results of this research will contribute to future editions of the new brazilian code, supplying inputs for use in future revisions.

Le sujet de cette thèse est l'hydrodynamique de corps minces (feuilles) et élancés (filamenteux) de fluide visqueux immergés dans un second fluide ayant une viscosité différente. Nous nous concentrons sur deux exemples : la subduction de la lithosphère océanique et le flambage de fils visqueux dans microcanaux divergents, les deux ont un nombre de Reynolds caractéristique Re<<1. Pour le cas de la subduction d'une feuille mince, nous proposons une hybride méthode «boundary integral & thin sheet» (BITS). Après la validation en comparant ses prévisions avec celles de la boundary-element méthode, deux solutions instantanées et dépendant du temps sont effectués pour analyser la subduction avec la méthode BITS. L'analyse à l'échelle de la vitesse d'immersion normalisée en fonction de «la rigidité en flexion» de la feuille est confirmée par nos prédictions numériques. Pour des rapports de viscosité modérée (≈100), la feuille amincit sensiblement quand elle coule, mais pas assez pour conduire à la «rupture de la dalle» que l'on observe dans plusieurs zones de subduction sur Terre. Ensuite, le code BLEU parallèle pour écoulements polyphasiques est utilisé à simuler pliage visqueux tridimensionnel dans des microcanaux divergent. Nous avons réalisé une étude paramétrique comprenant cinq simulations dans lequel le rapport de débit volumétrique, le rapport de viscosité, le nombre de Reynolds, et la forme de la chaîne ont été modifiées par rapport à un modèle de référence. Le fil devient instable à une instabilité de pliage en raison de la contrainte de compression longitudinale. L'axe de pliage initial peut être parallèle ou perpendiculaire à la dimension étroite de la chambre. Dans le premier cas, le pliage transforme lentement au pliage perpendiculaire au moyen d'une torsion, ou peut disparaître totalement. / The hydrodynamics of thin (sheet-like) and slender (filamentary) bodies of viscous fluid immersed in a second fluid with a different viscosity is studied. Here we focuses on two examples: the subduction of oceanic lithosphere and the buckling of viscous threads in diverging microchannels, both have a characteristic Reynolds number Re<<1. A hybrid boundary integral & thin sheet method (BITS) is build for the subduction of 2D immersed sheet. After the validation by comparing with the results of full boundary elements method, both instantaneous and time-dependant soloutions are done to analyze the subduction with the BITS method. The scaling analysis of the normalized sinking speed V/V_Stokes as a function of the sheet's 'flexural stiffness' is confirmed by our numerical predictions. For moderate viscosity ratios (≈100), the sheet thins substantially as it sinks, but not enough to lead to the ‘slab breakoff’ that is observed in several subduction zones on Earth. Next, the parallel code BLUE for multi-phases flows is used to simulate the 3-dimensional viscous folding in diverging microchannels. We performed a parameter study comprising five simulations in which the flow rate ratio, the viscosity ratio, the Reynolds number, and the shape of the channel were varied relative to a reference model. The thread becomes unstable to a folding instability due to the longitudinal compressive stress. The initial folding axis can be either parallel or perpendicular to the narrow dimension of the chamber. In the former case, the folding slowly transforms via twisting to perpendicular folding , or may disappear totally.

L’objectif de ce sujet de thèse est de prédire l’apparition des instabilités plastiques (striction diffuse et striction localisée) dans les matériaux métalliques. Ces matériaux sont décrits par des modèles de comportement élasto-plastique couplés à l’endommagement. L'approche de Lemaitre, reliant l'endommagement à la déformation plastique équivalente et au taux de restitution de la densité d'énergie élastique, est adoptée. Parmi les différents critères et indicateurs qui sont considérés pour la prédiction des instabilités matériau, la théorie de bifurcation et les critères de type force maximum sont tout particulièrement analysés et comparés. Un objectif important de cette étude consiste à déterminer les mécanismes déstabilisants clés associés à cette modélisation du comportement, ainsi que l’impact des différents aspects physiques et des paramètres matériau sur l’apparition de la striction. Les développements résultants sont appliqués à une sélection représentative de matériaux métalliques afin prédire leurs limites de formabilités. Cette approche combinant des lois de comportement et critères de striction peut être utilisée comme outil théorique et numérique d’aide à la conception de nouveaux matériaux à ductilité améliorée / The aim of the present work is to predict the occurrence of plastic instabilities (diffuse and localized necking) in thin sheet metals. The prediction of these plastic instabilities is undertaken using an elastic–plastic model coupled with ductile damage, which is then combined with various plastic instability criteria theory. The bifurcation-based criteria and the maximum force criterion used in this work are formulated within a general three-dimensional modeling framework, and then applied for the particular case of plane-stress conditions for sheet metals. Some theoretical relationships or links between the different investigated necking criteria are established, which allows a hierarchical classification in terms of their conservative character in predicting critical necking strains. The resulting numerical tool is implemented into the finite element code ABAQUS/Standard to predict forming limit diagrams, in both situations of a fully three-dimensional formulation and a plane-stress framework. This approach, that combines constitutive equations to necking criteria, serves as a useful tool in the design of new materials with improved ductility

Le présent travail de thèse s’inscrit dans le cadre d’un projet industriel proposé par une entreprise luxembourgeoise et en collaboration avec le Centre de Recherche Public Henry Tudor du Luxembourg (Laboratoire des Technologies Industriels (LTI)). L’objectif consiste à mettre au point une méthode numérique de détermination de la forme des outils d’emboutissage et du flan de pièces de précision en tôlerie fine pour que ce dernier, une fois déformé en une ou plusieurs opérations, correspond à la définition tridimensionnelle du cahier des charges. La méthode a pour objectif de remplacer une démarche expérimentale coûteuse par essais–erreur. Deux démarches numériques sont proposées, la première est relative à la détermination de la forme du flan. Elle consiste à estimer la forme du flan par Approche Inverse en partant de la forme 3D demandée. Puis, un logiciel de simulation incrémental par éléments finis en 3D est utilisé dans une procédure d’optimisation heuristique pour déterminer la forme du flan. Dans la deuxième démarche, il s’agit de déterminer la forme des outils d’emboutissage en utilisant le logiciel de simulation incrémental couplé avec une méthode de compensation du retour élastique en 2D. La démarche numérique est validée expérimentalement dans le cas d’un emboutissage réalisé en une ou plusieurs passes, à l’aide d’une presse manuelle, sans serre flan et avec des outils de forme très complexe. / The present study deals with an industrial project proposed by a luxembourgian enterprise and in collaboration with the luxembourgian research centre Henry Tudor (Laboratory of Industrial Technologies (LTI)). The main objective is to build a numerical approaches for the determination of the initial blank shape contour and tools shape for 3D thin metallic precision parts obtained by stamping, knowing the 3D CAD geometry of the final part. The purpose of the present procedure is to replace the expensive and time consuming experimental trial and error optimization method. Two numerical approaches have been proposed, the first is regarding the determination of the blank shape. An estimation of the blank shape can be given using the Inverse Approach. Update of the blank shape will then be continued by iterations combining heuristic optimization algorithms and incremental stamping codes. The second approach is based on precise finite element models and on spring-back compensation algorithm. The numerical approaches are tested in the case of a special stamping process where the parts are pressed in one or more steps using a manual press, without blank holder and by the mean of complex shape tools.