Integrative Computational Materials Engineering: Concepts and Applications of a Modular Simulation Platform

332 Pages·5.49 MB·English

Editedby
Georg J.SchmitzandUlrichPrahl
IntegrativeComputational
MaterialsEngineering
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Edited by Georg J. Schmitz and Ulrich Prahl
Integrative Computational
Materials Engineering
Concepts and Applications of a Modular
Simulation Platform
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V
Contents
ListofContributors XI
Preface XV
PartI Concepts 1
1 Introduction 3
GeorgJ.SchmitzandUlrichPrahl
1.1 Motivation 3
1.2 WhatIsICME? 4
1.2.1 The‘‘Unaries’’:I,C,M,andE 6
1.2.2 The‘‘Binaries’’ME,IM,IE,IC,CE,andCM 6
1.2.3 The‘‘TernarySystems’’:CME,ICM,IME,ICE 9
1.2.4 The‘‘Quaternary’’System:‘‘ICME’’ 10
1.3 HistoricalDevelopmentofICME 11
1.4 CurrentActivitiesTowardICME 13
1.5 TowardaModularStandardizedPlatformforICME 15
1.6 ScopeofThisBook 17
References 18
2 BasicConceptofthePlatform 21
GeorgJ.SchmitzandUlrichPrahl
2.1 Overview 21
2.2 OpenArchitecture 27
2.3 Modularity 28
2.3.1 IndividualModules 29
2.3.2 BridgingtheScales 30
2.3.3 InterfaceModules/Services 32
2.3.4 DataModules 33
2.4 Standardization 34
2.5 Web-BasedPlatformOperation 35
2.6 BenefitsofthePlatformConcept 36
2.6.1 BenefitsforSoftwareProviders 37
2.6.2 BenefitsforIndustrialUsers 38
VI Contents
2.6.3 BenefitsforAcademia,Education,andKnowledgeManagement 39
2.7 VerificationUsingTestCases 39
3 State-of-the-ArtModels,Software,andFutureImprovements 43
MarkusApelandGeorgJ.Schmitz
3.1 Introduction 43
3.2 OverviewofExistingModelsandSoftware 44
3.3 RequirementsforModelsandSoftwareinanICMEFramework 48
3.3.1 ModelQuality 50
3.3.2 ImprovingNumericalandModelAccuracy 50
3.3.3 SpeedingUpIndividualModelsandDistributedSimulations 52
3.3.4 InformationIntegrity 56
3.4 BenefitsofPlatformOperationsforIndividualModels 56
3.4.1 ImprovedQualityofInitialConditions 56
3.4.2 ImprovedQualityofMaterialsData 57
3.4.3 ConsiderationofLocalEffectiveMaterialsProperties 57
3.5 StrongandWeakCouplingofPlatformModels 58
3.6 Conclusions 59
References 59
4 Standardization 61
StefanBenkeandGeorgJ.Schmitz
4.1 Overview 61
4.2 StandardizationofGeometryandResultData 62
4.2.1 ExtendedFileHeader 64
4.2.2 GeometricAttributes 64
4.2.3 FieldData 65
4.3 MaterialData 65
4.4 ApplicationProgrammingInterface 70
4.4.1 USER MATERIAL TMSubroutine 72
4.4.2 USER MATERIAL HTSubroutine 74
4.4.3 USER EXPANSIONSubroutine 75
4.4.4 USER PHASE CHANGESubroutine 76
4.5 FutureDirectionsofStandardization 78
References 79
5 PredictionofEffectiveProperties 81
GottfriedLaschet,TatyanaKashko,StephanBenke,MehmetO¨te,and
KirstenBobzin
5.1 Introduction 81
5.2 HomogenizationofMaterialswithPeriodicMicrostructure 82
5.2.1 StaticEquilibriumofaHeterogeneousMaterial 82
5.2.2 PeriodicityandTwo-ScaleDescription 84
5.2.3 TheAsymptoticHomogenizationMethod 85
5.3 HomogenizationofMaterialswithRandomMicrostructure 88
Contents VII
5.3.1 MorphologyAnalysisandDefinitionoftheRVE 89
5.3.2 InfluenceoftheRVEPositionontheEffectiveElasticProperties 92
5.3.3 StochasticHomogenization 94
5.4 PostprocessingofMacroscaleResults:theLocalizationStep 96
5.5 DedicatedHomogenizationModel:Two-LevelRadialHomogenization
ofSemicrystallineThermoplastics 98
5.5.1 MechanicalPropertiesoftheAmorphousandCrystallinePhases 98
5.6 VirtualMaterialTesting 101
5.7 ToolsfortheDeterminationofEffectiveProperties 102
5.7.1 HomogenizationToolHOMATandItsPreprocessor
Mesh2Homat 102
5.7.2 ProgramEnvironmentforVirtualTesting 104
5.8 Examples 104
5.8.1 MethodsComparisonBasedonaBenchmark 105
5.8.2 Austenite–FerritePhaseTransformationofaFe–C–MnSteel 106
5.8.3 ApplicationoftheStochasticHomogenization:EffectiveThermal
ConductivityofanOpen-CellMetallicFoam 110
5.9 Conclusions 112
References 113
6 DistributedSimulations 117
ThomasBeer,TobiasMeisen,andRudolfReinhard
6.1 Motivation 117
®
6.2 TheAixViPMaP SimulationPlatformArchitecture 118
6.3 DataIntegration 122
6.4 Web-BasedUserInterfacefortheSimulationPlatform 125
References 128
7 Visualization 131
ThomasBeerandTobiasMeisen
7.1 Motivation 131
7.2 StandardizedPostprocessing 132
7.3 IntegratedVisualization 134
7.4 DataHistoryTracking 139
References 140
PartII Applications 143
8 TestCaseLinePipe 145
PatrickFayek,HendrikQuade,ThomasHenke,GottfriedLaschet,Markus
Apel,EduardoSambranoRossiter,MarkusBambach,andUlrichPrahl
8.1 Introduction 145
8.2 Materials 146
8.3 Process 147
8.3.1 OverviewofProcessChain 147
VIII Contents
8.3.2 Reheating 148
8.3.3 HotRolling 148
8.3.4 CoolingandPhaseTransformation 148
8.3.5 U-andO-Forming 149
8.3.6 Welding 150
8.4 Experiments 150
8.4.1 DilatometerExperiments 150
8.4.2 CompressionTeststoDetermineFlowCurvesandDRXKinetics 151
8.4.3 TensileTests 152
8.4.4 WeldingExperiments 152
8.5 ExperimentalProcessChain 153
8.6 SimulationModelsandResults 155
8.6.1 Reheating 155
8.6.2 HotRolling 161
8.6.3 CoolingandPhaseTransformation 164
8.6.4 U-andO-Forming 167
8.6.5 Welding 175
8.7 ConclusionandBenefits 183
References 184
9 TestCaseGearingComponent 187
SergeyKonovalov,ThomasHenke,UlrichJansen,ArioHardjosuwito,
WolframLohse,MarkusBambach,andUlrichPrahl
9.1 Introduction 187
9.2 Materials 188
9.3 TheProcessChain 189
9.3.1 Overview 189
9.3.2 HotRollingandForging 190
9.3.3 FPAnnealing 190
9.3.4 Machining 191
9.3.5 Carburizing 191
9.3.6 LaserWelding 192
9.4 ExperimentalProceduresandResults 192
9.4.1 OverviewofPhenomena 192
9.4.2 CharacterizationofDynamicRecrystallizationandGrainGrowth 193
9.4.3 CharacterizationofPhaseTransformations 194
9.4.4 InvestigationoftheParticleEvolutionalongtheProcessChain 195
9.4.5 CharacterizationofWeldingDepth 196
9.5 SimulationChainandResults 197
9.5.1 OverviewofSimulationChain 197
9.5.2 MacroscopicProcessSimulations 201
9.5.3 MicroscopicSimulations 212
9.6 Conclusions 217
References 218
Contents IX
10 TestCase:TechnicalPlasticParts 221
WalterMichaeli,ChristianHopmann,ThomasBaranowski,Gottfried
Laschet,BarbaraHeesel,TimArping,KirstenBobzin,TatyanaKashko,and
MehmetO¨te
10.1 Introduction 221
10.2 Material 222
10.2.1 Polypropylene 222
10.3 ProcessChain 223
10.4 ModelingofthePhenomenaalongtheProcessChain 224
10.4.1 CrystallizationofSemicrystallineThermoplastics 224
10.4.2 FormationofMolecularOrientations 227
10.4.3 EffectiveMechanicalPropertiesofSemicrystallineThermoplastics 229
10.4.4 MacroscopicMechanicalMaterialsBehavior 231
10.5 ImplementationoftheVirtualProcessChain 236
10.5.1 SigmaSoft 236
10.5.2 SphaeroSim 236
10.5.3 HOMAT 236
10.5.4 AbaqusFEA 237
10.5.5 SimulationChain 237
10.6 ExperimentalMethods 239
10.7 Results 241
10.7.1 MacroscopicProcessSimulation 241
10.7.2 MicrostructureSimulation 242
10.7.3 EffectiveMechanicalProperties 246
10.7.4 MacroscopicPartBehavior 251
10.8 SummaryandConclusion 253
References 255
11 Textile-ReinforcedPistonRod 257
BrittaKuckhoff,JosefKlingele,MarkusLinke,ThomasGries,Kirsten
Bobzin,ThomasSchla¨fer,TatyanaKashko,andMehmetO¨te
11.1 Introduction 257
11.2 ExperimentalProcessChain 258
11.2.1 TheBraidingProcess 259
11.2.2 TheInvestmentCastingProcess 261
11.3 SimulationChain 261
11.3.1 Overview 261
11.3.2 SimulationoftheBraidingProcess 262
11.3.3 SimulationoftheBraidingStructure 266
11.3.4 SimulationoftheInfiltrationProcess 267
11.3.5 SimulationoftheSolidificationMicrostructure 268
11.3.6 EffectiveAnisotropicMaterialProperties 271
11.3.7 EffectivePropertiesoftheComponent 276
11.4 Conclusion/Benefits 277
References 278
X Contents
12 TestCaseStainlessSteelBearingHousing 281
StephanFreyberger,StefanBenke,HendrikQuade,
andJennyRudnizki
12.1 Introduction 281
12.2 Materials 283
12.2.1 Overview 283
12.2.2 ThermophysicalProperties 283
12.3 Processes 284
12.3.1 OverviewoftheProcessChain 284
12.3.2 TheCastingProcess 284
12.3.3 TheHeatTreatmentProcess 285
12.3.4 TheMachiningProcess 285
12.3.5 TheApplication 286
12.4 Phenomena 286
12.4.1 OverviewofPhenomenatoBeModeled 286
12.4.2 DescriptionoftheIndividualPhenomena 286
12.5 SimulationChain 291
12.5.1 SimulationTools 291
12.5.2 SimulationFlowchart 291
12.6 Results 293
12.6.1 MacroscopicProcessSimulations 293
12.6.2 Microstructures 300
12.7 Conclusions/Benefits 303
References 303
13 FutureICME 305
UlrichPrahlandGeorgJ.Schmitz
13.1 ImperativeSteps 305
13.2 LessonsLearned 308
13.3 FutureDirections 315
13.3.1 EducationandTraining 316
13.3.2 Internationalization,Professionalization,andCommercialization 316
13.3.3 PlatformDevelopment 318
13.4 ClosingRemark 320
References 321
Index 323