A multiscale modeling approach was utilized to predict thickness reduction in steel plate heat exchangers (PHEs) utilized in combi boilers. The roles of texture and microstructure were successfully accounted for by properly coupling crystal plasticity and finite element analysis (FEA). In particular, crystal plasticity was employed to determine the proper multiaxial hardening rule to describe the material flow during the forming of PHEs, which was then implemented into the finite element (FE) metal-forming simulations. The current findings show that reliable thickness distribution predictions can be made with appropriate coupling of crystal plasticity and FEA in metal forming. Furthermore, the multiscale modeling approach presented herein constitutes an important guideline for the design of new PHEs with improved thermomechanical performance and reduced manufacturing costs.
Issue Section:
Research Papers
References
1.
Altan
, T.
, and Vazquez
, V.
, 1996
, “Numerical Process Simulation for Tool and Process Design in Bulk Metal Forming
,” CIRP Ann. Manuf. Technol.
, 45
(2
), pp. 599
–615
.2.
Gronostajski
, J.
, Matuszak
, A.
, Niechaiowicz
, A.
, and Zimniak
, Z.
, 2004
, “The System for Sheet Metal Forming Design for Complex Parts
,” J. Mater. Process. Technol.
, 157–158
, pp. 502
–507
.3.
Zimniak
, Z.
, 2000
, “Problems of Multi-Step Forming Sheet Metal Process Design
,” J. Mater. Process. Technol.
, 106
(1–3
), pp. 152
–158
.4.
Makinouchi
, A.
, 1996
, “Sheet Metal Forming Simulation in Industry
,” J. Mater. Process. Technol.
, 60
(1–4
), pp. 19
–26
.5.
Panthi
, S. K.
, Ramakrishnan
, N.
, Pathak
, K. K.
, and Chouhan
, J. S.
, 2007
, “An Analysis of Springback in Sheet Metal Bending Using Finite Element Method (FEM)
,” J. Mater. Process. Technol.
, 186
(1–3
), pp. 120
–124
.6.
Thibaud
, S.
, Hmida
, R. B.
, Richard
, F.
, and Malecot
, P.
, 2012
, “A Fully Parametric Toolbox for the Simulation of Single Point Incremental Sheet Forming Process: Numerical Feasibility and Experimental Validation
,” Simul. Modell. Pract. Theory
, 29
, pp. 32
–43
.7.
Reagan
, J.
, and Smith
, E.
, 1993
, Metal Spinning
, Bruce Publishing
, New York
.8.
Shanmuganatan
, S. P.
, and Senthil Kumar
, V. S.
, 2012
, “Experimental Investigation and Finite Element Modeling on Profile Forming of Conical Component Using Al 3003(O) Alloy
,” Mater. Des.
, 36
, pp. 564
–569
.9.
Senthil Kumar
, V. S.
, Viswanathan
, D.
, and Natarajan
, S.
, 2006
, “Theoretical Prediction and FEM Analysis of Superplastic Forming of AA7475 Aluminum Alloy in a Hemispherical Die
,” J. Mater. Process. Technol.
, 173
(3
), pp. 247
–251
.10.
Firat
, M.
, Kaftanoglu
, B.
, and Eser
, O.
, 2008
, “Sheet Metal Forming Analyses With an Emphasis on the Springback Deformation
,” J. Mater. Process. Technol.
, 196
(1–3
), pp. 135
–148
.11.
Roters
, F.
, Eisenlohr
, P.
, Hantcherli
, L.
, Tjahjanto
, D. D.
, Bieler
, T. R.
, and Raabe
, D.
, 2010
, “Overview of Constitutive Laws, Kinematics, Homogenization and Multiscale Methods in Crystal Plasticity Finite-Element Modeling: Theory, Experiments, Applications
,” Acta Mater.
, 58
(4
), pp. 1152
–1211
.12.
Inal
, K.
, Mishra
, R. K.
, and Cazacu
, O.
, 2010
, “Forming Simulation of Aluminum Sheets Using an Anisotropic Yield Function Coupled With Crystal Plasticity Theory
,” Int. J. Solids Struct.
, 47
(17
), pp. 2223
–2233
.13.
Lian
, J.
, Barlat
, F.
, and Baudelet
, B.
, 1989
, “Plastic Behaviour and Stretchability of Sheet Metals II. Effect of Yield Surface Shape on Sheet Forming Limit
,” Int. J. Plast.
, 5
(2
), pp. 131
–147
.14.
Asaro
, R. J.
, and Needleman
, A.
, 1985
, “Texture Development and Strain Hardening in Rate Dependent Polycrystals
,” Acta Metall.
, 33
(6
), pp. 923
–953
.15.
Verma
, R. K.
, Biswas
, P.
, Kuwabara
, T.
, and Chung
, K.
, 2014
, “Two Stage Deformation Modeling for DP 780 Steel Sheet Using Crystal Plasticity
,” Mater. Sci. Eng. A
, 604
, pp. 98
–102
.16.
Hu
, J.
, Jonas
, J. J.
, and Ishikawa
, T.
, 1998
, “FEM Simulation of the Forming of Textured Aluminum Sheets
,” Mater. Sci. Eng. A
, 256
(1–2
), pp. 51
–59
.17.
Tikhovskiy
, I.
, Raabe
, D.
, and Roters
, F.
, 2007
, “Simulation of Earing During Deep Drawing of an Al–3% Mg Alloy (AA5754) Using a Texture Component Crystal Plasticity FEM
,” J. Mater. Process. Technol.
, 183
(2–3), pp. 169
–175
.18.
Longue
, B.
, Dingle
, M.
, and Duncan
, J. L.
, 2007
, “Side-Wall Thickness in Draw Die Forming
,” J. Mater. Process. Technol.
, 182
(1–3
), pp. 191
–194
.19.
Osakada
, K.
, Mori
, K.
, Altan
, T.
, and Groche
, P.
, 2011
, “Mechanical Servo Press Technology for Metal Forming
,” CIRP Ann. Manuf. Technol.
, 60
(2
), pp. 651
–672
.20.
Canadinc
, D.
, Biyikli
, E.
, Niendorf
, T.
, and Maier
, H. J.
, 2011
, “Experimental and Numerical Investigation of the Role of Grain Boundary Misorientation Angle on the Dislocation–Grain Boundary Interactions
,” Adv. Eng. Mater.
, 13
(4), pp. 281
–287
.21.
Canadinc
, D.
, Sehitoglu
, H.
, Maier
, H. J.
, and Kurath
, P.
, 2008
, “On the Incorporation of Length Scales Associated With Pearlitic and Bainitic Microstructures Into a Visco-Plastic Self-Consistent Model
,” Mater. Sci. Eng. A
, 485
(1–2
), pp. 258
–271
.22.
Lebensohn
, R. A.
, and Tomé
, C. N.
, 1993
, “A Self-Consistent Anisotropic Approach for the Simulation of Plastic Deformation and Texture Development of Polycrystals: Application to Zirconium Alloys
,” Acta Metall. Mater.
, 41
(9
), pp. 2611
–2624
.23.
Kocks
, U. F.
, Tomé
, C. N.
, and Wenk
, H. R.
, 1998
, Texture and Anisotropy
, Cambridge University Press
, New York
.24.
Liu
, H.
, Yuan
, J. L.
, and Jin
, J.
, 2002
, “Visualization Simulations for a Cold Press Die
,” J. Mater. Process. Technol.
, 129
(1–3
), pp. 321
–325
.25.
Feng
, Z. Q.
, Vallee
, C.
, Fortune
, D.
, and Peyraut
, F.
, 2006
, “The 3é Hyperelastic Model Applied to the Modeling of 3D Impact Problems
,” Finite Elem. Anal. Des.
, 43
(1), pp. 51
–58
.26.
Onal
, O.
, Bal
, B.
, Toker
, S. M.
, Mirzajanzadeh
, M.
, Canadinc
, D.
, and Maier
, H. J.
, 2014
, “Microstructure-Based Modeling of the Impact Response of a Biomedical Niobium–Zirconium Alloy
,” J. Mater. Res.
, 29
(10
), pp. 1123
–1134
.27.
Onal
, O.
, Ozmenci
, C.
, and Canadinc
, D.
, 2014
, “Multi-Scale Modeling of the Impact Response of a Strain-Rate Sensitive High-Manganese Austenitic Steel
,” Front. Mater.
, 1
, p. 00016.28.
Li
, J.
, Li
, C.
, and Zhou
, T.
, 2012
, “Thickness Distribution and Mechanical Property of Sheet Metal Incremental Forming Based on Numerical Simulation
,” Trans. Nonferrous Met. Soc. China
, 22
(S1
), pp. 54
–60
.29.
Padmanabhan
, R.
, Oliveira
, M. C.
, Alves
, J. L.
, and Menezes
, L. F.
, 2007
, “Influence of Process Parameters on the Deep Drawing of Stainless Steel
,” Finite Elem. Anal. Des.
, 43
(14
), pp. 1062
–1067
.30.
Xie
, C. L.
, and Nakamachi
, E.
, 2002
, “Investigations of the Formability of BCC Steel Sheets by Using Crystalline Plasticity Finite Element Analysis
,” Mater. Des.
, 23
(1
), pp. 59
–68
.31.
Nguyen
, T.-D.
, Phan
, V.-T.
, and Bui
, Q.-H.
, 2015
, “Modeling of Microstructure Effects on the Mechanical Behavior of Ultrafine-Grained Nickels Processed by Severe Plastic Deformation by Crystal Plasticity Finite Element Model
,” ASME J. Eng. Mater. Technol.
, 137
(2
), p. 021010
.32.
Kirane
, K.
, Ghosh
, S.
, Groeber
, M.
, and Bhattachrjee
, A.
, 2009
, “Grain Level Dwell Fatigue Crack Nucleation Model for Ti Alloys Using Crystal Plasticity Finite Element Analysis
,” ASME J. Eng. Mater. Technol.
, 131
(2
), p. 021003
.Copyright © 2015 by ASME
You do not currently have access to this content.
