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Metals
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Computational Methods in Metal Manufacturing Processes
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Computational Methods in Metal Manufacturing Processes

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (30 September 2021) | Viewed by 8442

Special Issue Editors

Prof. Dr. Eric Feulvarch

E-Mail Website
Guest Editor
Laboratoire de Tribologie et Dynamique des Systèmes, Écully, France
Interests: computational mechanics; computational methods in manufacturing processes; nonlinear multi-physical models; FEM and XFEM; nitriding and carbo-nitriding processes; spot welding (SPW) processes; friction stir welding (FSW) processes; fusion welding processes (MAG); additive manufacturing (AM) processes
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Hamid Zahrouni

E-Mail Website
Guest Editor
Université de Lorraine, Nancy, France
Interests: solid mechanics; structural analysis; numerical modeling; engineering, applied and computational mathematics; nonlinear analysis; finite element modeling; finite element analysis; mechanics of materials; FE analysis; stress analysis

Special Issue Information

Dear Colleagues,

Virtual manufacturing is attracting increased interest for its capability to improve or invent product designs while respecting a responsible life cycle. The industrial application of virtual manufacturing requires the development of new efficient numerical strategies for simple calibration, easy use, and fast results, despite the complexity of the nonlinear coupled problems that must be solved.

This Special Issue, entitled “Computational Methods in Metal Manufacturing Processes”, will focus on this purpose. Our goal is to publish a notable issue on this topic, covering areas including (but not limited to) assembling processes; bulk and sheet metal forming; machining, drilling, and grinding processes; additive manufacturing; tribology and surface engineering processes; control and optimization of manufacturing processes; modeling and numerical methods for forming and manufacturing processes, including constitutive modeling for forming and manufacturing of metals, reduced order modeling (ROM), and proper generalized decomposition (PGD).

Prof. Eric Feulvarch
Prof. Hamid Zahrouni
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • computational methods
  • simulation
  • virtual manufacturing
  • metal
  • forming processes

Published Papers (4 papers)

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Research

18 pages, 4392 KiB  
Article
Study of the Thermal History upon Residual Stresses during the Dry Drilling of Inconel 718
by Kévin Chenegrin, Denis Bouscaud, Mathieu Girinon, Habib Karaouni, Jean-Michel Bergheau and Eric Feulvarch
Metals 2022, 12(2), 305; https://doi.org/10.3390/met12020305 - 10 Feb 2022
Cited by 1 | Viewed by 1421
Abstract
The main objective of this article was to show for the first time that heat transfer plays a major role in residual stress generation during the dry drilling of Inconel 718, and to propose a numerical strategy capable of simulating such thermo-mechanical phenomena. [...] Read more.
The main objective of this article was to show for the first time that heat transfer plays a major role in residual stress generation during the dry drilling of Inconel 718, and to propose a numerical strategy capable of simulating such thermo-mechanical phenomena. An X-ray diffraction (XRD) analysis shows that without lubrication, high tensile residual stresses can be observed on the surface of a deep through drilled hole. Such a situation can be highly detrimental for the fatigue lifetime of a mechanical component. A thermal history in five phases is first identified by means of temperature measurements exhibiting an overheating of approximately 500 ∘C on the created hole surface just before the end of the drilling operation. A 3D thermo-viscoplastic model is herein improved in terms of boundary conditions to show that this phenomenon is triggered by the progressive decrease in the Inconel 718 volume under the cutting zone. To the authors’ knowledge, such a phenomenon has never been reported and simulated before in the literature. Then, a 3D thermo-elasto-plastic simulation including elasticity is proposed to compute residual stresses from the thermal results of the previous model. It shows for the first time that the overheating stage induces sufficiently intense plasticity to produce high tensile residual stresses of approximately 900 MPa as we experimentally observed. Full article
(This article belongs to the Special Issue Computational Methods in Metal Manufacturing Processes)
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19 pages, 3790 KiB  
Article
Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy
by Eva Anglada, Fernando Boto, Maider García de Cortazar and Iñaki Garmendia
Metals 2021, 11(11), 1747; https://doi.org/10.3390/met11111747 - 31 Oct 2021
Cited by 2 | Viewed by 2216
Abstract
Simulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but [...] Read more.
Simulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is the long calculation time. In order to apply optimization strategies in the design process or to implement online predictive systems, faster models are required. One solution is the use of surrogate models, also called metamodels or grey-box models. The novelty of the work presented here lies in the development of several metamodels for the HPDC process. These metamodels are based on a gradient boosting regressor technique and derived from a physics-based finite element model. The results show that the developed metamodels are able to predict with high accuracy the secondary dendrite arm spacing (SDAS) of the cast parts and, with good accuracy, the misrun risk and the shrinkage level. Results obtained in the predictions of microporosity and macroporosity, eutectic percentage, and grain density were less accurate. The metamodels were very fast (less than 1 s); therefore, they can be used for optimization activities or be integrated into online prediction systems for the HPDC industry. The case study corresponds to several parts of aluminum cast alloys, used in the automotive industry, manufactured by high-pressure die casting in a multicavity mold. Full article
(This article belongs to the Special Issue Computational Methods in Metal Manufacturing Processes)
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21 pages, 5057 KiB  
Article
Validation of a Microstructure-Based Model for Predicting the High Strain Rate Flow Properties of Various Forms of Additively Manufactured Ti6Al4V(ELI) Alloy
by Amos Muiruri, Maina Maringa and Willie du Preez
Metals 2021, 11(10), 1628; https://doi.org/10.3390/met11101628 - 13 Oct 2021
Cited by 4 | Viewed by 1738
Abstract
To increase the acceptance of direct metal laser sintered Ti6Al4V(Extra Low Interstitial—ELI) in industry, analytical models that can quantitatively describe the interrelationships between the microstructural features, field variables, such as temperature and strain rate, and the mechanical properties are necessary. In the present [...] Read more.
To increase the acceptance of direct metal laser sintered Ti6Al4V(Extra Low Interstitial—ELI) in industry, analytical models that can quantitatively describe the interrelationships between the microstructural features, field variables, such as temperature and strain rate, and the mechanical properties are necessary. In the present study, a physical model that articulates the critical microstructural features of grain sizes and dislocation densities for use in predicting the mechanical properties of additively manufactured Ti6Al4V(ELI) was developed. The flow stress curves of different microstructures of the alloy were used to obtain and refine the parameters of the physical model. The average grain size of a microstructure was shown to influence the athermal part of yield stress, while the initial dislocation density in a microstructure was seen to affect the shape of the flow stress curve. The viscous drag effect was also shown to play a critical role in explaining the upturn of flow stress at high strain rates. The microstructure-based constitutive model developed and validated in this article using experimental data showed good capacity to predict the high strain rate flow properties of additively manufactured Ti6Al4V(ELI) alloy. Full article
(This article belongs to the Special Issue Computational Methods in Metal Manufacturing Processes)
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20 pages, 7069 KiB  
Article
Process Signature for Laser Hardening
by Friedhelm Frerichs, Yang Lu, Thomas Lübben and Tim Radel
Metals 2021, 11(3), 465; https://doi.org/10.3390/met11030465 - 11 Mar 2021
Cited by 15 | Viewed by 2273
Abstract
During many manufacturing processes for surface treatment of steel components heat will be exchanged between the environment and the workpiece. The heat exchange commonly leads to temperature gradients within the surface near area of the workpiece, which involve mechanical strains inside the material. [...] Read more.
During many manufacturing processes for surface treatment of steel components heat will be exchanged between the environment and the workpiece. The heat exchange commonly leads to temperature gradients within the surface near area of the workpiece, which involve mechanical strains inside the material. If the corresponding stresses exceed locally the yield strength of the material residual stresses can remain after the process. If the temperature increase is high enough additionally phase transformation to austenite occurs and may lead further on due to a fast cooling to the very hard phase martensite. This investigation focuses on the correlation between concrete thermal loads such as temperature and temperature gradients and resulting modifications such as changes of the residual stress, the microstructure, and the hardness respectively. Within this consideration the thermal loads are the causes of the modifications and will be called internal material loads. The correlations between the generated internal material loads and the material modifications will be called Process Signature. The idea is that Process Signatures provide the possibility to engineer the workpiece surface layer and its functional properties in a knowledge-based way. This contribution presents some Process Signature components for a thermally dominated process with phase transformation: laser hardening. The target quantities of the modifications are the change of the residual stress state at the surface and the position of the 1st zero-crossing of the residual stress curve. Based on Finite Element simulations the internal thermal loadings during laser hardening are considered. The investigations identify for the considered target quantities the maximal temperature, the maximal temperature gradient, and the heating time as important parameters of the thermal loads. Full article
(This article belongs to the Special Issue Computational Methods in Metal Manufacturing Processes)
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