Investigations on Residual Stresses within Hot-Bulk-Formed Components Using Process Simulation and the Contour Method

authored by: Bernd Arno Behrens, Jens Gibmeier, Kai Brunotte, Hendrik Wester, Nicola Simon, Christoph Kock
Abstract: Residual stresses resulting from hot-forming processes represent an important aspect of a component’s performance and service life. Considering the whole process chain of hot forming, the integrated heat treatment provided by a defined temperature profile during cooling offers a great potential for the targeted adjustment of the desired residual stress state. Finite element (FE) simulation is a powerful tool for virtual process design aimed at generating a beneficial residual stress profile. The validation of these FE models is typically carried out on the basis of individual surface points, as these are accessible through methods like X-ray diffraction, hole-drilling, or the nanoindentation method. However, especially in bulk forming components, it is important to evaluate the quality of the model based on residual stress data from the volume. For these reasons, in this paper, an FE model which was already validated by near surface X-ray diffraction analyses was used to explain the development of residual stresses in a reference hot forming process for different cooling scenarios. Subsequently, the reference process scenarios were experimentally performed, and the resulting residual stress distributions in the cross-section of the bulk specimens were determined by means of the contour method. These data were used to further validate the numerical simulation of the hot forming process, wherein a good agreement between the contour method and process simulation was observed.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Karlsruhe Institute of Technology (KIT)
Type: Article
Journal: Metals
Volume: 11
ISSN: 2075-4701
Publication date: 31.03.2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all)
Electronic version(s): https://doi.org/10.3390/met11040566 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{d0dafcf998f64bf7b55e289376ef47e4,
title = "Investigations on Residual Stresses within Hot-Bulk-Formed Components Using Process Simulation and the Contour Method",
abstract = "Residual stresses resulting from hot-forming processes represent an important aspect of a component{\textquoteright}s performance and service life. Considering the whole process chain of hot forming, the integrated heat treatment provided by a defined temperature profile during cooling offers a great potential for the targeted adjustment of the desired residual stress state. Finite element (FE) simulation is a powerful tool for virtual process design aimed at generating a beneficial residual stress profile. The validation of these FE models is typically carried out on the basis of individual surface points, as these are accessible through methods like X-ray diffraction, hole-drilling, or the nanoindentation method. However, especially in bulk forming components, it is important to evaluate the quality of the model based on residual stress data from the volume. For these reasons, in this paper, an FE model which was already validated by near surface X-ray diffraction analyses was used to explain the development of residual stresses in a reference hot forming process for different cooling scenarios. Subsequently, the reference process scenarios were experimentally performed, and the resulting residual stress distributions in the cross-section of the bulk specimens were determined by means of the contour method. These data were used to further validate the numerical simulation of the hot forming process, wherein a good agreement between the contour method and process simulation was observed.",
keywords = "Contour method, FE simulation, Hot forming, Residual stress",
author = "Behrens, {Bernd Arno} and Jens Gibmeier and Kai Brunotte and Hendrik Wester and Nicola Simon and Christoph Kock",
note = "Funding Information: Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)? 374871564 (BE 1691/223-2) and 374768210 (GI 376/13-2) within the priority program SPP 2013. Klaus Simon from the Institute of Production Science (wbk) at Karlsruhe Institute of Technology (KIT) is gratefully acknowledged for providing CMM measurements. We would also like to express our thanks to Mike Prime from Los Alamos National Laboratory (US), who introduced us to the application of the contour method. ",
year = "2021",
month = mar,
day = "31",
doi = "10.3390/met11040566",
language = "English",
volume = "11",
journal = "Metals",
issn = "2075-4701",
publisher = "Multidisciplinary Digital Publishing Institute",
number = "4",
}