In this paper, Finite Element method and full-scale experiments have been used to study a hot forging method for fabri-cation of a spindle using reduced initial stock size. The forging sequence is carried out in two stages. In the first stage, the hot rolled cylindrical billet is pre-formed and pierced in a closed die using a spherical nosed punch to within 20 mm of its base. This process of piercing or impact extrusion leads to high strains within the work piece but requires high press loads. In the second stage, the resulting cylinder is placed in a die with a flange chamber and upset forged to form a flange. The stock mass is optimized for complete die filling. Process parameters such as effective strain distribution, material flow and forging load in different stages of the process are analyzed. It is concluded from the simulations that minor modifications of piercing punch geometry to reduce contact between the punch and emerging vertical walls of the cylinder appreciably reduces the piercing load. In the flange chamber, a die surfaces angle of 52° instead of 45° is pro-posed to ensure effective material flow and exert sufficient tool pressure to achieve complete cavity filling. In order to achieve better compression, it is also proposed to shorten both the length of the inserted punch and the die “tongues” by a few mm.

To manage China’s growing demands of electricity, more and larger dams could be a part of the solution. It is important to evaluate and perform safety analysis for existing dams, in order to improve our understanding and knowledge about future dams. In this master thesis, a safety research of Longtan Dam on the Hongshui River in China was analysed. The main objectives in this research were to construct a 3D model and determine the critical points of large stress, strain and yield area in the dam for different cases.The factor of safety for sliding when primary loads were acting on the dam was calculated to be 0.50 for the non-overflow section of the dam and 0.48 for the overflow section. A safety factor against overturning was also calculated for the non-overflow and overflow section to 2.24 and 1.96 respectively. The results showed that the dam was safe from both sliding and overturning. The numerical results for distribution of stress, strain and yield area were simulated in 3D models by using ANSYS, a finite element program. Several cases for non-overflow and overflow sections of Longtan Dam were analysed for different heights and load combinations. For the first three cases where only self-weight was applied on the dam, high impacts of stress and strain were located at the dam heel, toe and at the largest maintenance tunnel of the dam. Appearance of plastic strain was also found around these areas. However, when primary loads were applied to the dam sections, the values of stress and strain became larger, especially in the toe area. In the last case when the dam was subjected to seismic activity, the distribution of stress and strain along the z-direction (along the dam) showed an uneven distribution, hence showing the importance of simulation in 3D.

Aluminium foam has a range of properties that are desirable in many applications. These properties include good stiffness and strength to weight ratios, impact energy absorption, sound damping, thermal insulation and non combustibility. Many of these characteristics are particularly attractive for core materials within sandwich structures. The combination of aluminium foam cores with thermoplastic composite skins is easily manufactured and has good potential as a multifunctional sandwich structure useful in a range of applications. This thesis has investigated the flexural behaviour of such structures using a combination of experimental and modelling techniques. The development of these structures towards commercial use requires a thorough understanding of the deformation and strain mechanisms of the structure, and this will, in turn, allow predictions of their structural behaviour in a variety of loading conditions. ¶ The experimental research involved the use of an advanced 3D optical measuring technique that produces realtime, full-field strain evolution during loading. This experimental characterisation of strain evolution in this class of sandwich structure under flexural loading is the first of its kind in the world. The experimental work studied the sandwich structure undergoing four-point bend testing. Initial studies compared the behaviour of the aluminium foam structure with a more traditional polymer foam sandwich structure. The aluminium foam structure was found to have equivalent or improved mechanical properties including more ductile deformation and an enhanced energy absorption. An investigation was conducted on the effect of core and skin thickness on the metal structure and a range of flexural behaviours were observed. Analysis of the strain distribution showed a complex development including localised effects from the non-uniform cellular structure of the material. An understanding of the variation with size is important in establishing design methods for utilising these structures. In particular, it is desirable that finite element simulations can be used to predict behaviour of these structures in a diverse range of loading conditions. This aspect was considered in the second half of this study. An existing constitutive model for aluminium foam, developed for use in compression energy absorption studies, was used to investigate finite element simulations of the flexural behaviour of the sandwich structure. The FE model was able to predict the general deformation behaviour of the thinner skinned structures although the magnitude of the load-displacement response was underestimated. It is suggested this may be related to the size effect on the input parameter characterisation. The strain distribution corresponded well with the experimental strain measurements. It was found a simple increase in the material model input parameters was able to more closely match the magnitude of the load-displacement response while maintaining the appropriate strain distribution. The general deformation shape of the model with the thicker skin corresponded reasonably well with the experimental observations. However, further work is necessary on the element failure criterion to capture the shear cracking observed. The strain distributions of the model predicted this failure with high strain concentrations matching those of the experimental contours. The last part of the thesis describes a parametric study on the effect of the foam material model input parameters on the flexural behaviour of the sandwich structure model. An important conclusion of this work is that this material model for aluminium foam can, with some development, be utilized to provide a viable method for simulating aluminium foam composite sandwich structures in flexural loading situations.

Thermally bonded nonwovens are low-price substitutes for traditional textiles. They are used in many areas including filtration, automotive and aerospace industries. Hence, understanding deformation behaviours of these materials is required to design new products tailored for specific applications in different areas. Because of their complex and random structure, numerical simulations of nonwoven materials have been a challenging task for many years. The main aim of the thesis is to develop a computational modelling tool to simulate the effect of design parameters on structural behaviour of low-density nonwoven materials by using a finite element method. The modelling procedure is carried out with a parametric modelling technique, which allows a designer to run a series of analyses with different design parameters and observe the effects of these parameters on the mechanical behaviour of nonwoven materials. The thesis also presents the study of rate dependent behaviour of nonwoven fibres. Novel test and data-interpretation procedures are proposed to determine the creep behaviour of fibres in the nonwoven structure. Some case studies are presented to demonstrate the effectiveness of the model. The developed computational tool allows macro and micro-scale structural investigation of nonwoven materials. Two additional studies are presented, performed with the developed tool. In the first study, the effect of design parameters on tensile stiffness of nonwovens was determined by performing numerical analyses with various nonwoven models. In the second one, strain distribution in fibres is studied thoroughly together with factors affecting the distribution. The models, developed in the thesis can also be employed in further studies of nonwovens, such as investigation of their damage and fracture behaviour.

Applying the anisotropy of magnetic susceptibility to analogue models provides detailed insights into the strain distribution and quantification of deformation within contractional tectonic settings like fold-and-thrust belts (FTBs). Shortening in FTBs is accommodated by layer-parallel shortening, folding, and thrusting. The models in this research reflect the different deformation processes and the resulting magnetic fabric can be attributed to thrusting, folding and layer-parallel shortening. Thrusting develops a magnetic foliation parallel to the thrust surface, whereas folding and penetrative strain develop a magnetic lineation perpendicular to the shorting direction but parallel to the bedding. These fabric types can be observed in the first model of this study, which simulated a FTB shortened above two adjacent décollements with different frictional properties. The different friction coefficients along the décollements have not only an effect on the geometric and kinematic evolution of a FTB, but also on the strain distribution and magnitude of strain within the belt.  The second series of models performed in this study show the development of a thrust imbricate and the strain distribution across a single imbricate in more detail. Three models, with similar setup but different magnitudes of bulk shortening, show strain gradients by gradual changes in principal axes orientations and decrease in degree of anisotropy with decreasing distance to thrusts and kinkzones. These models show that at the beginning of shortening, strain is accommodated mainly by penetrative strain. With further shortening, formation of thrusts and kinkzones overprint the magnetic fabric locally and the degree of anisotropy is decreasing within the deformation zones. At thrusts, an overprint of the magnetic fabric prior deformation towards a magnetic foliation parallel to the thrust surfaces can be observed. A rather complex interplay between thrusting and folding can be analysed in the kinkzones. In general, this thesis outlines the characteristics of magnetic fabric observed in FTBs, relates different types of magnetic fabric to different processes of deformation and provides insights into the strain distribution of FTBs.

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Les aciers inoxydables austéno-ferritiques présentent une microstructure biphasée dans laquelle se mêlent austénite et ferrite. Leurs caractéristiques mécaniques élevées ainsi que leur bonne tenue en corrosion en font un candidat sérieux pour remplacer les aciers inoxydables austénitiques. Malheureusement, la faible forgeabilité de ces alliages rend la fabrication de tôles particulièrement critique. En effet, le phénomène de « crique de rive » est fréquemment rencontré au cours des étapes du laminage à chaud. Par conséquent, cela nécessite des opérations supplémentaires comme le découpage des rives, ce qui aboutit à une augmentation des coûts de production. Les différents facteurs influençant la ductilité à chaud de ces aciers sont passés en revue afin d'identifier quels sont les zones d'ombres. La synthèse bibliographique révèle deux zones d'ombres : d'une part, le manque d'un essai de ductilité à chaud permettant de discriminer différentes microstructures en terme de résistance à la propagation de fissure à haute température ; et d'autre part l'absence de données quantitative concernant la partition de la déformation entre la ferrite et l'austénite lors des étapes de mise en forme à chaud. Le concept de travail essentiel de rupture a été appliqué à hautes températures. Il a été démontré que cette méthode est fiable et discriminante pour quantifier la résistance à la propagation de fissure à haute température. Elle permet également de générer un paramètre physique pertinent pour optimiser les microstructures par rapport à un mode de mise en forme donné. La technique conventionnelle de micro-grilles a été adaptée de manière à cartographier à haute température les déformations à l'échelle de la microstructure. Cette technique fournit en plus des résultats qualitatifs concernant les mécanismes de déformations, des données quantitatives à propos de la partition de la déformation entre la ferrite et l'austénite. Ces données peuvent être utilisées afin de valider les modèles qui prédisent le comportement à chaud des aciers duplex pendant les premières étapes du laminage à chaud. Les deux outils developpés au cours de cette étude permettent de donner des solutions pour éviter le phénomène de « crique de rives ». / The Duplex Stainless Steels (DSS) are defined as a family of stainless steels consisting of a two-phase microstructure involving δ-ferrite and γ-austenite. Exceptional combinations of strength and toughness together with good corrosion resistance under critical working conditions designate DSS a suitable alternative to conventional austenitic stainless steels. Unfortunately, the relatively poor hot workability of these alloys makes the industrial processing of flat products particularly critical. Cracking of the coils during hot rolling along the edges is frequently reported. As a consequence, additional operations like grinding, discontinuous processing or scraping are often required, leading to increased manufacturing costs. The different parameters affecting the hot working of duplex stainless steels have been reviewed in order to identify which are the missing pieces of the puzzle. The bibliographical review reveals that two pieces are missing in the hot workability puzzle. On the one hand, it is necessary to develop a new hot ductility test which allows discriminating microstructures in terms of high temperature tearing resistance, and on the other hand, quantitative data about the strain partitioning between ferrite and austenite during the hot working operations are needed. The Essential Work of Fracture concept has been applied at high temperature. It has been demonstrated that this method is a reliable and discriminating tool for quantifying the high temperature tearing resistance and to generate a physically relevant index to guide the optimization of microstructures towards successful forming operations. A modified micro-grid technique has been developed to experimentally simulate the local state of deformation of different duplex microstructures at high temperature. This technique provides qualitative results about the deformation features as well as quantitative data about the strain partitioning between ferrite and austenite. The micro-strain distributions measured can be used to validate the models predicting the hot deformation of duplex stainless steels during the roughing-mill operations. The two tools developed in this investigation allow suggesting possible remedies for the edge cracking phenomenon.