Integrated Computational Materials and Production Engineering (ICMPE)

 
Vision



Design, extension, application and assessment of a modular platform in the material, process and production design process for high value products.
Objectives
phase 2

(1) Design and establishment of a platform for Integrative Computational Materials and Production Engineering (ICMPE)
(2) Exploitation of sensitivity/ robustness and optimization of product creation chains with focus on component and microstructure history
(3) Set up of a model map for virtual material production chains

 
  Figure 1

As part of the sub-project, a simulation platform for integrative development of materials and process chains has been developed. This simulation platform is used for the numerical development of a low-cost hardened steel 18CrNiMo7-6-Subst with reduced nickel contents for large transmission gears. The simulation chain describes the following processes at macro and micro levels: casting/ solidification, forging, heat treatment, machining, hobbing, case hardening/ tempering and final mechanical properties.

 
  Figure 1 IEHK

Using the mathematical formulations, a chemical composition was calculated for a steel to fulfill defined hardenability requirements. By this, an alloying concept for a low cost substitutional steel with significantly reduced Nickel content has been designed. In B2 project part two different materials were analyzed – 18CrNiMo7-6 steel and the newly designed low cost substitutional steel.

The combination of finite element and phase field simulation provides the requirements for as-cast structure and casting parameters, which offers to avoid the hot crack formation on the surface during continuous casting and ensure the stable fine grain structure at the end of the process chain.

  Figure 1 IEHK

Using the mathematical formulations, a chemical composition was calculated for a steel to fulfill defined hardenability requirements. By this, an alloying concept for a low cost substitutional steel with significantly reduced Nickel content has been designed. In B2 project part two different materials were analyzed – 18CrNiMo7-6 steel and the newly designed low cost substitutional steel.

The combination of finite element and phase field simulation provides the requirements for as-cast structure and casting parameters, which offers to avoid the hot crack formation on the surface during continuous casting and ensure the stable fine grain structure at the end of the process chain (Figure 1).

To describe the microstructure evolution during hot deformation, a semi-empirical microstructure model was determined. Combined with the FE-process model this allows for the prediction of temperature distribution, grain size evolution and residual stresses. To validate the microstructure model, simulation results were compared with forging experiments resulting in good agreement.

  Figure 1 IEHK

Using the mathematical formulations, a chemical composition was calculated for a steel to fulfill defined hardenability requirements. By this, an alloying concept for a low cost substitutional steel with significantly reduced Nickel content has been designed. In B2 project part two different materials were analyzed – 18CrNiMo7-6 steel and the newly designed low cost substitutional steel.

The combination of finite element and phase field simulation provides the requirements for as-cast structure and casting parameters, which offers to avoid the hot crack formation on the surface during continuous casting and ensure the stable fine grain structure at the end of the process chain (Figure 1).

To describe the microstructure evolution during hot deformation, a semi-empirical microstructure model was determined. Combined with the FE-process model this allows for the prediction of temperature distribution, grain size evolution and residual stresses. To validate the microstructure model, simulation results were compared with forging experiments resulting in good agreement.

The 3D FEM simulation of warm forging, besides producing the ordinal stress and strain distribution data, is able to describe the recrystallization region during processing based on the dynamic material model (DMM) as a function of the precipitates state.

A coupled Eulerian-Lagrangian model was developed for machining simulation. The complete chip formation was not observed, since the residual stress remains in the workpiece.

The simulations of the pulse vacuum carburizing are completely realized for 18CrNiMo 7-6 and the designed substitute material. The thermodynamic and kinetic DICTRA databases are reliable for carburization simulation, according to the final carbon profile predicted by simulations and the experimentally obtained microhardness distribution – which is in good agreement with prescribed case hardening specifications. Furthermore, the finite element-based simulations demonstrate the evolution of phase transformations and residual stresses properly.

The new simulation platform allows for modelling the lifetime of a gear depending on parameters such as the material and its inclusions, the manufacturing process, modifications that were applied during the manufacturing process and the overall macro geometry. This holistic approach to determine the load carrying capacity of a gear by means of an FE-method grants the possibility to change any of the aforementioned parameters and know their influence on the life time.

The properties of plastic components were analyzed and simulated. The plastic platform focusses the multi scale, microstructure based shrinkage and warpage simulation of semi-crystalline, plastic components made by injection molding.

 
 
 
 
 
 

For more information, please visit our page of the technical demonstrator.