Institute of Fundamental Technological Research

This report presents the modeling of pressure-assisted sintering within the framework of a multiscale approach. Three individual numerical methods have been collectively applied to predict the behavior of a sintering body at three different scales. The appropriate solutions to connect each model/scale have been proposed. Molecular dynamics have been employed to evaluate the grain boundary diffusion coefficient at the atomistic scale. The obtained results of diffusive parameters have been transferred to the micromechanical model of sintering. Here, the discrete element method was used to represent the sintered material properties at the microscopic scale. Micromechanical based results have been validated by own experimental data of material density evolution, indicating the required coincidence. The transfer from micro- to the macroscopic model has been realized by determining the macroscopic viscous moduli from discrete element simulations and subsequently applying them to the continuum model of sintering. The numerical results from finite element simulations at the macroscopic scale have been compared with discrete element ones.

sintering, multiscale modeling, discrete element method, molecular dynamics, finite element method

The NUMPRESS System has been developed in IPPT PAN as a result of a project financially supported by European Regional Development Fund (within the Innovative Economy Programme) and is dedicated to small and middle enterprises dealing with sheet metal forming. The program consists of (i) an analytical module for analysis of forming processes with the finite element method, (ii) an optimization module controlling execution of the analytical module and performing optimization with respect to selected process parameters, in both deterministic and robust formulation, (iii) a reliability analysis module controlling execution of the analytical module to assess how random distribution of design parameters affects forming results, and (iv) a graphical user interface enabling communication between modules and easy definition of design parameters and optimization criteria. The analytical module consists of two independent programs up to the user's choice: NUMPRESS-Flow, a faster and less accurate program for implicit quasi-static analysis of rigid-viscoplastic shells (based on the flow approach) and NUMPRESS-Explicit, a program for explicit dynamical analysis of elastic-plastic and elastic-viscoplastic shells. Both programs are interfaced to a well-known commercial graphical pre- and postprocessor GiD. Fundamentals of formulations employed in the system and numerical examples are presented in the paper.

sheet metal forming, finite element method, deterministic and robust design optimization, reliability analysis

Niniejsza praca dotyczy procedury poszukiwania kontaktu w symulacji numerycznej procesu tłoczenia blach. W pracy zaproponowano poprawkę do standardowego algorytmu poszukiwania kontaktu, pozwalającą na wyeliminowanie możliwych błędów polegających na źle wskazanym elemencie kontaktowym, bądź wskazaniu braku takiego elementu, co w konsekwencji prowadzi do błędnych wyników symulacji. Ponadto w pracy przeanalizowano koszt numeryczny przedstawionego algorytmu.

analiza kontaktu, tłoczenie blach

This paper presents modelling of both single and double-phase powder sintering processes at the macroscopic level. In particular, its constitutive formulation, numerical implementation and numerical tests are described. The macroscopic constitutive model is based on the assumption that the sintered material is a continuous medium. The parameters of the constitutive model for material under sintering are determined by simulation of sintering at the microscopic level using a micro-scale model. Numerical tests were carried out for a cylindrical specimen under hydrostatic and uniaxial pressure. Results of macroscopic analysis are compared against the microscopic model results. Moreover, numerical simulations are validated by comparison with experimental results. The simulations and preparation of the model are carried out by Abaqus FEA - a software for finite element analysis and computer-aided engineering. A mechanical model is defined by the user procedure “Vumat” which is developed by the first author in Fortran programming language. Modelling presented in the paper can be used to optimize and to better understand the process.

Educational assessment, Hydrostatics, Computer simulation, Finite-element analysis, Programming languages, Sintering

This paper presents modeling of a sintering process at various scales. Sintering is a powder metallurgy process consisting in consolidation of powder materials at elevated temperature but below the melting point. Sintering models at the atomistic, microscopic and macroscopic scales have been presented. Sintering is a process governed by diffusion therefore the atomistic modeling using the molecular dynamics has been focused on investigation of the diffusion process. The micromechanical model has been developed within the framework of the discrete element method. It allows us to consider microstructure and its changes during sintering. The macroscopic model is based on the continuum phenomenological approach. It combines elastic, thermal and viscous creep deformation. The methodology to determine macroscopic quantities: stress, strains and constitutive viscous properties from the discrete element simulations has been presented. Possibilities of the developed models have been demonstrated by applying them to simulation of sintering of the intermetallic NiAl powder. Own experimental results have been used to calibrate and validate numerical models.

sintering, modeling, discrete element method, diffusion, molecular dynamics, macroscopic model

This paper presents modelling of double-phase powder sintering processes at the macroscopic level. In particular, its constitutive formulation, numerical implementation and numerical simulations are described. Numerical tests were carried out for a cylindrical specimen under uniaxial pressure and are compared against the microscopic model results. The model has been developed within the framework of a MUSINT project which is carried on in Institute of Fundamental Technological Research, Warsaw, Poland. The overall objective of the MUSINT (Multiscale numerical modelling of sintering processes) is development of numerical models allowing us to analyse at various scales manufacturing processes employing sintering as the main technological stage.

finite element method, sintering, multiscale modelling, double-phase composite

This document presents modelling of single-phase powder sintering processes at the macroscopic level. In particular, its constitutive formulation, numerical implementation and numerical test are described. Numerical tests were carried out for a cylindrical specimen under hydrostatic and uniaxial pressure. Results of macroscopic analysis are compared against the microscopic model results.

sintering porcesses, numerical analysis, multiscale modelling

sintering, discrete element method, multi-scale modeling

sintering, constitutive model

sintering, multiscale modelling

This paper presents NUMPRESS System that has been developed in IPPT PAN as a result of a project financially supported by European Regional Development Fund (within the Innovative Economy Programme) and is dedicated to small and middle enterprises dealing with sheet metal forming. It seems undoubted that efficient design of an industrial sheet forming process requires reliable computer simulations and a tool for numerical optimization of the process parameters. It has to be also admitted that. among small and medium enterprises (SME) in this industrial branch, there are many who do not use any such numerical tools in their practice.
Computer simulation of sheet metal forming processes is a very specific branch of computational mechanics. Finite element systems dedicated strictly to this kind of processes are needed and actually present on the market. Commercial systems (like Autoform, PAM-Stamp, Stampack, etc.) are, due to their prices, usually beyond financial ability of SME.

Design of the drawing process and tools, i.e. choice of proper values of several design parameters, require efficient optimization strategy. In this process, random character of at least some of the parameters has to be taken into account. In view of this fact, the traditional, deterministic approach to optimization is insufficient and elements of robust design optimization techniques and reliability analysis have to be included in the formulation of the optimization problem. It has to be admitted that, even if some of the mentioned commercial simulation systems offer numerical optimization modules, not all of them reach beyond the deterministic concept of the optimization process.

sheet metal forming, finite element method, deterministic and robust design optimization, reliability analysis

This paper presents basic features of the NUMPRESS system and some examples ofuse. The system has been developed at IPPT PAN as a result of a project financially supported by European Regional Development Fund and is dedicated to small and middle enterprises (SME) dealing with sheet metal forming. The program consists of (i) an analytical finite element method module (ii) an optimization module, (iii) a reliability analysis module, and (iv) a graphical user interface enabling communication between modules. The analytical module consists of two independent programs up to the user’s choice: NUMPRESS-Flow, a faster and less accurate program for implicit quasi-static analysis of rigid-viscoplastic shells (based on the flow approach) and NUMPRESS-Explicit, a program for explicit dynamical analysis of elastic-plastic shells. Both programs are interfaced to a well-known commercial graphical pre-and postprocessor GiD.

sheet metal forming, finite element method, deterministic and robust design optimization, reliability analysis

finite element method, contact analysis, sheet metal forming