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European Network for Alloys Behaviour Law Enhancement

Periodic Reporting for period 1 - ENABLE (European Network for Alloys Behaviour Law Enhancement)

Reporting period: 2018-02-01 to 2020-01-31

The European Training Network actively involves academics and industrial partners in training a new generation of young researchers for the future of manufacturing. By developing new solutions for forecasting and mastering processes relevant for all factories using metallic alloys, ENABLE proposes a complete rethink of the usual process simulation methods. Innovative multiscale (from microscopic to macroscopic scales), and multi-physics (strong thermomechanical and microstructural couplings) are addressed multi-level advanced (TRL 1 to 8) simulation.
The modelling proposed by ENABLE can be used to create specifically tailored material microstructures to improve the components’ performance. These advances will lead to the development of new tools better suited to production with reduced premature wear, increased service life, improved tools, etc. and will reduce production time and thereby production costs.
A group of 9 Early Stage Researchers will be trained within world leading research teams. They will be introduced to novel approaches and applications while exploiting advances in fundamental research. To “enable” this vision, each trainee will join a team of closely integrated world-class experts in mechanical science, materials science and computer science/numerical methods.
Additional cross-disciplinary training (intellectual property, patenting, entrepreneurship, communication, open science, gender balance awareness, etc.) and a strong involvement on the part of the 12 Industries, SMEs, and research centres will provide the students with transferable skills and complementary competencies which will improve their research abilities and enhance their future employability.
The ever-increasing emphasis on sustainable growth has affected mechanical engineering tremendously. Nowadays, components and products must be efficient, durable and lightweight.
Manufacturing is often only seen as a step in creating a product as efficiently as possible without “too many negative side effects” on the component. This is usually the driving force of design for manufacture. Innovative solutions to reduce costs and weight without compromising performance require mastery of the entire manufacturing process. Each manufactured part is the result of the cumulative effect of the various processes encountered along the whole manufacturing chain.
The mechanical properties of metal alloys are commonly used in industrial shaping processes to produce components meeting specific requirements. Manufacturers must optimize their production processes to meet the high demand for new products of greater value in terms of accessibility, quality, productivity and profitability.
The presence of complex phenomena related to fields such as continuum mechanics, thermo- mechanics, metallurgy and chemistry complicates attempts to control these processes. These phenomena are even more complex in the presence of high stains, high strain rates and high thermal gradients. Predicting the final mechanical state of a structure subjected to dynamic loading involves numerical calculations that require a complete description of the materials’ dynamic behaviour. This description requires the choice of the best model, in terms of both algorithmic calculation code relevance and mechanical relevance.
The main scientific achievements of the WPs are:
Several tests have been performed by ESR1 and ESR2:
Compression tests with Split-Hopkinson and Gleeble
The microscopic analysis of the deformed samples have been realised with :
Optical microscope and SEM using EDX and EBSD, in order to account for recrystallisation (RX), plastic strain, grain growth. precipitation evolution.
Analysis of the mechanical tests results using MATLAB and optimisation of the flow stress curves using Generic Model Platform (GMoP), a MATLAB based platform developed at LTU.
The design and development of a new test bench (Dynamic torsion device): the new test bench is designed to observe the thermomechanical behaviour of the material under a medium strain rate and at high temperature.A new alternative method has been developed by changing the shape of the specimen in order to obtain a dominant shear by performing the traditional tensile and compression test.
WP2 :
The following new concepts and efficient computing methods have been highlighted at the midterm period of the project :
Innovative thermomechanical constitutive setting for strain gradient crystal plasticity and its finite element implementation and for Cosserat viscoplasticity and its finite element implementation;
A significant speedup for a scientific application in the cloud compared to an on-premise supercomputer environment. Moreover, in the context of ENABLE, this new HPC environment offers many advantages compared to the previous setup in terms of reliability, efficiency, packaging and distribution of software.
At the midterm period of the project, standard cases have been defined, in order to respond to the usual materials in industrial cases, to metallurgical evolutions representative of current phenomena and according to today's knowledge. Efforts were concentrated on the design of experimental benches, able to measure fields for each process.
The identification of optical parameters for temperature and kinematic fields measurement, with experimental campaigns, have been done for machining and FSW (with robot and turning machine-tool) processes and existing in-situ monitoring systems were studied on commercial machines for sensitivity analysis for Additive Manufacturing Process.
New processes, both substractive and additive, for new and improved materials (new alloys, composites, multimaterial parts, etc.) must be addressed to strengthen European leadership in manufacturing technologies. Two new experimental benches (for dynamic torsion, cutting and friction) have been designed and they will be ready soon and the results obtained will be innovative and they will have an impact on the scientific state of the art.The ENABLE proposal is fully in line with several of the research priorities defined in relevant European initiatives, such as the FoF - Factories of the Future PPP (public-private partnership). Aspects related to process modelling are addressed both at current work-programmes for the FoF calls and at the EFFRA (European Factories of the Future Research Association22) roadmap. Material models that are able to directly capture the evolution of the structure and its influence on mechanical behaviour are thus in great demand, as they can cover a wider range of conditions and reduce the characterisation effort. The economic benefits of such material approaches are relevant, considering the cost of the experimental tests and the effort put into identifying the model parameters, which often requires a tedious iterative process. By offering much better predictive capabilities for extreme solicitations, new perspectives in terms of processing conditions and weight reduction can also be offered. CAE vendors who can deliver such material approaches for industrial simulations will have a very strong competitive advantage, especially in the fields of sheet metal forming, machining, additive manufacturing and impact simulation. Considering the size of these markets, the economic impact in the long term can be estimated at several million Euro per year for the CAE industry alone, and much larger figures for the end users.
ENABLE Progress Review 2019