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  • About
  • The Global ETD Search service is a free service for researchers to find electronic theses and dissertations. This service is provided by the Networked Digital Library of Theses and Dissertations.
    Our metadata is collected from universities around the world. If you manage a university/consortium/country archive and want to be added, details can be found on the NDLTD website.
1

Semi-solid constitutive modeling for the numerical simulation of thixoforming processes.

Koeune, Roxane 14 June 2011 (has links)
Semi-solid thixoforming processes rely on a material microstructure made of globular solid grains more or less connected to each other, thus developing a solid skeleton deforming into a liquid phase. During processing, the material structure changes with the processing history due to the agglomeration of the particles and the breaking of the grains bonds. This particular evolutive microstructure makes semi-solid materials behave as solids at rest and as liquids during shearing, which causes a decrease of the viscosity and of the resistance to deformation while shearing. Thixoforming of aluminum and magnesium alloys is state of the art and a growing number of serial production lines are in operation all over the world. But there are only few applications of semi-solid processing of higher melting point alloys such as steel. This can partly be attributed to the high forming temperature combined with the intense high temperature corrosion that requires new technical solutions. However the semi-solid forming of steels reveals high potential to reduce material as well as energy consumption compared to conventional process technologies, such as casting and forging. Simulation techniques exhibit a great potential to acquire a good understanding of the semi-solid material process. Therefore, this work deals with the development of an appropriate constitutive model for semi-solid thixoforming of steel. The constitutive law should be able to simulate the complex rheology of semi-solid materials, under both steady-state and transient conditions. For example, the peak of viscosity at start of a fast loading should be reproduced. The use of a finite yield stress is appropriate because a vertical billet does not collapse under its own weight unless the liquid fraction is too high. Furthermore, this choice along with a non-rigid solid formalism allows predicting the residual stresses after cooling down to room temperature. Several one-phase material modeling have been proposed and are compared. Thermo-mechanical modeling using a thermo-elasto-viscoplastic constitutive law has been developed. The basic idea is to extend the classical isotropic hardening and viscosity laws to the non solid state by considering two non-dimensional internal parameters. The first internal parameter is the liquid fraction and depends on the temperature only. The second one is a structural parameter that characterizes the degree of structural build up in the microstructure. Those internal parameters can depend on each other. The internal parameters act on the the viscosity law and on the yield surface evolution law. Different formulations of viscosity and hardening laws have been proposed and are compared to each other. In all cases, the semi-solid state is treated as a particular case, and the constitutive modeling remains valid over the whole range of temperature, starting from room temperature to above the liquidus. These models are tested and illustrated by mean of several representative numerical applications.

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