Materials and Manufacturing Process Modelling

Dear Colleagues,

Understanding the mechanical behavior of material during the manufacturing process is critical for process optimization and producing parts with good quality. Such knowledge will enable a reduction in the carbon footprint when manufacturing strain-hardening-sensitive or nonhomogeneous materials. Over the years, mechanistic, empirical, and numerical models were extensively developed to simulate manufacturing processes or material mechanical behavior. However, limited published models can integrate the influence of material microstructure constituents together with manufacturing processes for process planning. One of the key factors for any manufacturing process simulation is the reliable mechanical behavior of material data. The most challenging aspect to simulating the effect of different percentages of material microstructure constituents in any manufacturing process is acquiring the stress strain curves experimentally. This can be overcome by designating specific elements that are more sensitive to strain hardening or strain rates when using finite element methods. Such an approach can reduce the dependence of experimental data, which are time consuming and costly to acquire. Furthermore, it can also simulate the mechanical behavior of metallic additive manufacturing materials. The general criteria used for process optimization are usually based on the temperature and stress field generated. However, for strain-hardening-sensitive materials with low thermal diffusivity, residual stresses and part distortion should be considered during process planning. Unfortunately, residual stress depth profiles are costly and time consuming to acquire.

In this Special Issue of JMMP, we are interested in contributions that focus on topics such as:

• Methodology to simulate the different microstructure constituents of steel or titanium, etc., on mechanical behavior.
• Advancement of representative volume element (RVE) models applied to manufacturing processes.
• Prediction of the effects of process parameters and tooling on surface integrity when processing materials with non-isotropic behavior such as carbon fiber-reinforced plastic.
• Use of numerical or mechanistic models to simulate the effect of tool geometry and process parameters when drilling stack or “sandwich” materials.
• Development of numerical or empirical methods to simulate the effects of material defects generated from additive manufacturing on mechanical properties.
• Modeling of the effect of additive manufacturing process parameters on surface and subsurface damage.
• Prediction of the influence of process parameters on surface integrity and/or burr formation during large strain deformation.
• Simulation of the effects of phase transformation induced by manufacturing processes on residual stresses.
• Multi-variable numerical or empirical models to predict the effects of tool coating characteristics such as thickness, micro cutting edge geometry, friction properties, and surface roughness for metal cutting or metal forming processes.
• Modeling of the effects of manufacturing environments (high-pressure cutting, minimal quantity lubricant, cryogenic cooling) on subsurface residual stresses after large strain deformation.

Prof. Dr. Eu-Gene Ng
Guest Editor

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