Simulating the evolution of non-metallic inclusions during the forging process

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Journal of Manufacturing Science and Engineering-transactions of The Asme Pub Date : 2023-03-01 DOI:10.1115/1.4057026
Brandon T. Mackey, T. Siegmund, M. Sangid
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引用次数: 1

Abstract

Radial forging of metallic materials requires both high temperatures and large plastic deformation. During this process, non-metallic inclusions (NMIs) can debond from the metallic matrix and break apart, resulting in a linear array of smaller inclusions, known as stringers. The evolution of NMIs into stringers can result in matrix load shedding, localized plasticity, and stress concentrations near the matrix-NMI interface. Due to these factors, stringers can be detrimental to the fatigue life of the final forged component, especially when present near a free surface. By performing a finite element model of the forging process with cohesive zones to simulate material debonding, we contribute to the understanding of processing induced deformation and damage sequences on the onset of stringer formation for both Type 1 and Type 2 alumina NMIs in a Ni-200 matrix. Through a parametric study, the interactions of forging temperature, strain rate, strain per pass, and interfacial decohesion on the NMI damage evolution metrics are studied, specifically NMI particle separation, rotation, and cavity formation. For Type 2 alumina NMIs, embedded in a Ni-200 matrix, the simulations indicate that at temperatures below 800 °C, particle separation dominates the NMI damage sequences, whereas at temperatures between 900 °C - 1000 °C, below an interfacial bond strength of 178 MPa, cavity formation is the dominate damage evolution mechanism, resulting in matrix load shedding and stress concentrations around the NMI.
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模拟锻造过程中非金属夹杂物的演变
金属材料的径向锻造需要高温和大的塑性变形。在这个过程中,非金属夹杂物(NMI)可以从金属基体上剥离并断裂,从而形成较小夹杂物的线性阵列,称为桁条。NMI向桁条的演变可能导致基体减载、局部塑性和基体NMI界面附近的应力集中。由于这些因素,桁条可能对最终锻造部件的疲劳寿命有害,尤其是当存在于自由表面附近时。通过对具有内聚区的锻造过程进行有限元模型以模拟材料脱粘,我们有助于理解Ni-200基体中1型和2型氧化铝NMI在桁条形成开始时的加工引起的变形和损伤序列。通过参数研究,研究了锻造温度、应变速率、单程应变和界面脱粘对NMI损伤演化指标的相互作用,特别是NMI颗粒分离、旋转和空腔形成。对于嵌入Ni-200基体中的2型氧化铝NMI,模拟表明,在800°C以下的温度下,颗粒分离主导了NMI损伤序列,而在900°C至1000°C之间,在178MPa的界面结合强度以下,空穴形成是主导的损伤演化机制,从而导致NMI周围的基体减载和应力集中。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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