Tata Consultancy Services Limited
Meeting original equipment manufacturers (OEM) specified mechanical property by designing polycrystalline alloys is challenging for designers and manufacturing industries. Such designs are done in assistance with modelling and simulations for specific alloy chemistry considering cost and time for physical experiments. To augment this design process, in this work we present a novel atomistically assisted microstructure and crystallographic texture-based accelerated alloy design framework based on multiscale modelling. We demonstrate its capability for automotive applications (example, deep drawn cylindrical aluminium cups for fuel tank component) by improving formability of aluminium AA5xxx series alloys through tailoring of chemistry and manufacturing process parameters. This multiscale modeling framework provides an example of optimizing formability for aluminium alloys to obtain a defect free (no cracks) stamped part using a novel integrated approach. It provides guidelines to designers for obtaining optimal alloy chemistry and manufacturing process parameters like amount of deformation, temperature, blank holder force, etc. during cold rolling, annealing and stamping processes which leads to desired microstructure including texture to meet the formability requirements for sheet metal during stamping. Forming limit diagram (FLD) required as input to finite element method (FEM) based stamping model for component level simulation to obtain defect free part is obtained using crystal plasticity based forming limit diagram prediction model which is accelerated by spectral-databases (SCP-FLD). This model takes inputs of post annealed microstructure and texture obtained from representative volume element (RVE) level cellular automata (CA) model of static recrystallization (SRX) during annealing process. Some of the inputs to CA SRX model are cold rolled microstructure and texture, along with parameters like mobilities and activation energies. First principles based-atomistic level molecular dynamics (MD) simulation in used in this work for calculation of mobility and activation energy bypassing the need for physical experiments to calculate these parameters for every new alloy chemistry. For inverse design the limiting FLD requirement from stamping simulation can be passed to lower length-scale models to obtain design set points in rolling and annealing process (for a specific chemistry). This will give the required material FLD with optimized microstructure and texture to meet stamping process requirements as set by designers.
Abstract
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