Computers in Materials Technology. Proceedings of the International Conference Held at the Institute of Technology, Linköping University, Sweden, June 4–5, 1980

201 Pages·1981·13.563 MB·English

by  T. Ericsson

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COMPUTERS
IN
MATERIALS TECHNOLOGY
Proceedings of the International Conference held at the
Institute of Technology, Linkôping University,
Sweden, June 4-5, 1980
Edited by
T. ERICSSON
Institute of Technology, Linkôping University, Sweden
PERGAMON PRESS
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All Rights Reserved. No part of this publication may be
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First edition 1981
British Library Cataloguing in Publication Data
Ericsson, T.
Computers in materials technology.
1. Materials science - Congresses
2. Electronic digital computers - Congresses
I. Title
620. Π TA403
ISBN 0-08-027570-2
These proceedings were reproduced by means of the
photo-offset process using the manuscripts supplied by the
authors of the different papers. The manuscripts have
been typed using different typewriters and typefaces. The
lay-out, figures and tables of some papers did not agree
completely with the standard requirements; consequently
the reproduction does not display complete uniformity.
To ensure rapid publication this discrepancy could not be
changed; nor could the English be checked completely.
Therefore, the readers are asked to excuse any deficiencies
of this publication which may be due to the above men-
tioned reasons.
The Editors
Printed in Great Britain by A. Wheaton & Co. Ltd., Exeter
CONFERENCE COMMITTEE
P.-E. Danielsson, Department of Systems Engineering, Institute of
Technology, Linköping University
T. Ericsson, Department of Mechanical Engineering, Institute of
Technology, Linköping University
T. Johannesson, Department of Mechanical Engineering, Institute of
Technology, Linköping University
B. G. A. Persson, Department of Mechanical Engineering, Institute of
Technology, Linköping University
v
PREFACE
The computer has become a necessary tool in many areas of science and
is now conquering the machinery industry by CAD and CAM. Materials
technology has been slow to adopt computer methods. It was therefore
felt that a survey of present computer applications in materials tech-
nology should be useful and could act as an inspiration for further
work. Thus an international conference titled "The computer in mate-
rials technology" was organised at the institute of technology,
Linköping University, Sweden, June 4-5 1980. A broad selection of
applications was included covering
Materials selection including computer data banks of
metals and polymers
Heat treatment and hardenability control of steel
Phase diagram calculations
Alloy design and composite materials design
Quantitative metallography
A couple of contributions did not quite fit into the given themes but
rather point to the fact that the list of themes could have been made
longer. I am thinking of for instance, the use of.computers in the
laboratory both for control of testing equipment and for dataprocess-
ing. A further step in the control direction would lead to process
control in for instance rolling and heat treatment of steel. Some
lectures touched upon solid mechanics methods, and of course one
could argue that fracture mechanics calculations and FEM methods
should have been included. One obvious reason for the present limited
choice of themes was the size of the conference. Another, particularly
relevant to solid mechanics methods was that they are well established
computer methods. At the conference we wanted to show the possibilities
of computer methods in areas where it has not been used extensively
before.
At the end of the conference the question was raised if the computer
has changed the character of the work within the themes. The answer
was for materials selection, heat treatment of steel, alloy design
and quantitative metallography it is beginning to change while for
composite materials design and phase diagram calculation the computer
has already become a necessary tool.
The practical administration of the conference was carried out by
our short course administration with its director Leif Bolin. Many
thanks to his unvaluable help. And many thanks to his secretary
Ingrid Nyman. Thanks are also due to the Swedish Board of Technical
Development for generously sponsoring the conference.
vii
COMPUTERIZED MATERIALS
PROPERTIES STORAGE, RETRIEVAL
AND USE
James A. Graham
Deere & Company Technical Center, Moline, IL, USA
ABSTRACT
This presentation will consists of a brief description of the Deere
& Company Materials Properties Data Bases. These include data for
steels, cast irons and plastics. The properties are on computer file
and are searchable by numerous material properties and material iden-
tification.
Programs are in use both in the Engineering Offices and at test sites,
whereby the properties are automatically used in programs to predict
the life of components. Other programs useful in manufacturing plann-
ing use the material property information to select the optimum
machining parameters.
A brief description will be given of activities of other organizations
in the US in developing computerized data bases of mechanical proper-
ties .
KEYWORDS
Properties; computer; data files; retrieval; analysis; fatigue;
selection.
INTRODUCTION
I would like to relate one example of the use of the computer in materials technology.
For several years, the farm equipment and automotive industries have been developing
improved procedures for predicting the initiation of fatigue and crack growth so these
tendencies could be avoided during the design process. We found, by making these
predictions, we can greatly reduce the time and effort required to develop machines that
meet our durability and reliability requirements.
3
4
In order to be able to predict the crack initiation and crack growth in fatigue, one must
know the magnitude and number of load cycles imposed upon the part under
consideration, and the temperature and corrosive atmosphere associated with the
product in service. In addition to this, one must know the properties of the material in the
service environment in order to determine whether or not yielding, fatigue or fracture will
take place. The success in predicting service life is directly proportional to the ability to
measure both the material and service load conditions.
Deere has devoted much attention to quantifying the service, the loads, number of cycles
and environment on products during the past 25 years. Telemetry, with 32-channel
capability, is used to transmit signals from the test vehicle to the trailer. The data are
recorded on tape or disk packs, and are analyzed immediately by a computer in the trailer.
The field computer can also be tied to the laboratory computer by telephone connection.
We also have the need to record data during long-term testing, using instrumentation
that does not require operator attendance. Therefore, we obtained what is called a
histogram recorder. This device is a small, square instrument which can be attached to
any flat surface. The recorder has been used on customer machines where we often
detect even higher loads than those measured on our experimental machines. It is also
being used on machines being transported by rail to measure the loads imposed on our
product in transit.
DEVELOPMENT OF THE SYSTEM
In order to appreciate the service data and acquisition system, one must understand the
output and how the system was developed. In the planning stages we decided how the
results would be used. We needed a number of procedures for predicting fatigue failure,
crack initiation, crack propagation and the critical crack lengths to develop final fracture.
We also needed load measurements to apply to our products during laboratory testing to
simulate field loadings. Since we are working with soils and crops, we find it essential to
be able to measure and compare the severity of the test conditions from field to field, and
from one year to the next.
In order to complete the design cycle, we needed load information useful in computer
models for analyzing subsequent design. In reviewing the requirements to develop output
for all of these uses, we found there were a number of elements needed; and many were
common to several types of analyses we wanted to perform. These are:
1. Service data collection
2. Selection of peaks and valleys of load histories
3. Simultaneous loads at several points
4. Storage of data
5. Data processing
6. Output formats
In many cases the elements are common to all or a number of the systems, including the
output of graphs, charts and statistical analysis on a CRT. By displaying all of the elements
in this manner, we were able to conserve time and effort by multiplying many common
aspects of the computer programs. We thus developed a modular system where we could
use portions of many of the programs to generate several types of output.
To make predictions of fatigue life and other failure modes, we store the material
properties used on a computer disk. When operating the system in the field, it is only
necessary to designate material present at each measurement location to use the
properties stored on disk. The operator can then ask the computer to print out numerical
properties of significance in predicting the fatigue life. With this information and the
loadings on the part, we can predict the life at each of the gauge locations. The output of
our life predictions are shown in Figure 1. One essential output of the service
measurements is the strain histogram shown in Figure 2.
5
Another quite useful output is the plotting of the life as a function of the ratio of strain to
load in Figure 3. This is useful in arriving at the size of a part, to obtain the desired life. If we
find that a part size needs to be changed, we can obtain information from curves and
determine the strain to load ratio required to obtain the desired life of the part. Another
useful output is one that predicts the crack growth as a function of the operating time, and
also the final crack length to cause failure as shown in Figure 4.
Now that I have described a part of the output for a field data acquisition system, I would
like to discuss the diagram in Figure 5. It shows the field computer, with inputs of the
MACHINE: EXPERIMENTAL PLOW DATE 11JUN76
LOCATION^ HOHNE, ILLINOIS TEST TIME: 4 MIN 3 SEC
CONDITIONS^ EXTRA DRY SOIL TEST ENGINEER: EPPLIN
RUN NUMBER 1
OPERATION: PLOWING IN ROCKY SOIL
CHANNEL GAGE CALIBRATION MATERIAL STRESS MAX MIN. LIFE
MICRO-STRAIN CONCENTR STRAIN STRAIN HRS
1 GA9 1500. X1045 HR 1.7 334. -67 0.306E+04
2 GA10 1500. Χ1Θ45 HR 1.7 127? 99. 0.122E+04
3 GAU 15ΘΘ. Χ1Θ45 HR 1.7 875. -363. 0.840E+03
4 GA12 1500. 1020 HR 1.7 556. -352. 0.764E+03
6 GA17 1500 A22H HR 1.7 944 -517. Θ.346Ε+04
? GA18 1500. X1045 HR 17 654 -125 0.178E+05
9 GA14 1500. X1045 HR 10 5531. -4320. 0.307E+01
10 GA5 1500. 1020 HR 1.0 107 1 -4334. β 861E+01
11 GA16 1500. 1045 QT* 2.0 6Θ8. -458. 0.664E+11
FIG 1. OUTPUT OF LIFE PREDICTIONS
MACHINE' EXPERIMENTAL PLOW DATE: 11JUN76
LOCATION: HOLINE,ILLINOIS TEST TIME: 4 MIN 3 SEC
CONDITIONS' EXTRA DRY SOIL TEST ENGINEER EPPLIN
RUN NUMBER 1
OPERATION' PLOWING IN ROCKY SOIL
CHANNEL NUMBER : 2
MAXIMUM STRAIN = 1277. MICRO STRAIN MINIMUM STRAIN = 99. MICRO STRAI
28. -
25. -
22. -
19. -
15. -
12. -
9. -
6. -
3. - EjU
II MM ΓΠ I | I I I I I I I I I I 1 I I M Π M I
1237
247 NOMINAL sti&IN RANGE <M1CR0 STRAIN)
FIG 2. OUTPUT OF SERVICE MEASUREMENTS
£L
MACHINE EXPERIMENTAL MACHINI DATE 21JUN76
LOCATION^ HOLINE,ILLINOIS TEST ENGINEER·· EPPLIN
CONDITIONS: LOU MOISTURE LOAD OPERATING IN ROCKY SOIL
MAXIMUM LOAD 141. N MATERIAL 414Θ HR
1Θ2
KIJ III
STRAIN
LOAD 4_ 1 II
lllll I ' ll
EJJJ
Tin
IN.
AKF-2.75
T* Hltr
1Θ1 1β< 19* 18" 10s
LIFE (HOURS)
FIG 3. PLOT OF LIFE PREDICTION
(STRAIN TO LOAD RATIO)
MACHINE SAE TEST DATA DATE 23APP77
LOCATION HOLINE/ ILL TEST TIME 60 MIN Θ SEC
TEST ENGINEER GALLIART RUN NUMBER 3
CONDITIONS LAB TEST
OPERATION CHEVROLET HISTORY
GAGE GA3 MATERIAL MAN-TEN
CLOSURE STRAIN 663.
GEO DESCRIPT SAE 35<A/B< 73
FINAL
INITIAL
3 0 6 8 9 Θ 1 \
1Θ 1 10 1 10 1
LIFE (HOURS) 102
FIG 4. CRACK LENGTH TO FAILURE PREDICTION
7
service loads, environment, and other measurements we make while operating
equipment, and the material properties stored in the computer file. From this information,
using the programs available, we can generate the output listed on the right-hand side of
the diagram. This system was designed with the user in mind, specifically, to make it
easier to train people throughout the Company to use the field data acquisition systems.
The fact that we have nine of these systems throughout the world demonstrates their
usefulness and reliability as a design and development tool. I look upon this as a miniature
of the type of system that should be developed for use in the total design, analysis, and
manufacturing planning of our products.
REFINEMENT OF THE SYSTEM
Considerable attention is now being devoted to a more comprehensive system. At the
request of the applied mechanics engineers from our factories, we now have a Task Force
to aid in enhancing the data presently available, adding to it data on other materials as
well as updating the information now in the field computers. We are accumulating a
number of data files, including the one on high-volume steels and cast irons. This data,
used most frequently to predict crack initiation and crack growth, has been generated in
recent years by university programs, Deere, and other companies using this same type of
information. We feel we have the most comprehensive file of property information of this
nature that exists in the world today. We are able to put confidence levels on some
properties so we have the ability to make better predictions at low failure rates. Another
set of data was developed for a specific application: this is the aluminums which have
potential for use in diesel-engine pistons.
One of our first selection guides was on plastics. In order to obtain information on a large
variety of plastics, we formerly resorted to manufacturers' published data. We now have
information on 44 properties and characteristics of 2700 different plastic formulations in
a data bank. This data file can be accessed in a batch mode, giving one the ability to select
those plastics meeting one or more of the 44 different characteristics. We use the
information published by the manufacturers somewhat differently than we do the
information on the steels where we know they are actual observed, verified and
statistically analyzed data.
CRACK INITIATION
MATERIALS CRACK PROPAGATION
PROPERTIES
STRAIN CYCLE COUNTS
LOAD HISTORIES -
SIMULTANEOUS — VARIABLE
FIELD STRAIN
COMPUTER TO LIFE ANALYSIS
LOAD
SEVERITY OF TEST CONDITIONS
EQUIVALENT CONSTANT -
AMPLITUDE LOAD
SERVICE LOADS
AND
PERFORMANCE ANALYSIS
ENVIRONMENT
FIG 5. FIELD DATA ACQUISITION SYSTEM
CIMT b