Pre-Conference Courses

COURSE 1: Bulk Forming simulation

The course participants will learn principles of numerical modeling for volumetric metal forming processes. The workshop topics will include predicting defects and estimation of tool fatigue for hot bulk forging, simulation of elastoplastic deformation of the workpiece and tools for cold bulk forming, as well as special methods for numerical simulation of open die forging, ring rolling, screw rolling and longitudinal rolling processes. Special attention will be paid to the phase transformations and grain size evolution analysis during deformation and heat treatment. The course participants will also gain practical skills in preparation of initial data for numerical simulation as well as interpretation of simulation results in modern commercial software. Computers with simulation software and interesting training examples will be provided to participants.

  • Numerical simulation of bulk metal forming processes
  • Hot forging: prediction of material flow defects and tool fatigue analysis
  • Cold bulk forming: simulation of coupled elastic-plastic deformation and workpiece damage analysis
  • Simulation of longitudinal, screw rolling, open die forging and ring rolling processes using dual-mesh method
  • Simulation of phase transformations during heat treatment of forged parts
  • Analysis of microstructure evolution processes in metal forming

 

COURSE 2: Hot stamping simulation

Industrial process simulation, e.g. of the press-hardening of manganese boron steel 22MnB5, which became a standard material used in automotive safety structures, needs to take into account the microstructural changes during the production process. The workshop gives a general introduction to models for phase transformations. The experimental determination of the phase transformations and their kinetics with dilatometer tests and the data preparation are addressed in the first part of the workshop with 22MnB5 as an example. In the second part a material card for LS-DYNA, based the calculated transformation kinetics and the experimental data, will be created. With this material card we setup a thermo-mechanical coupled simulation with LS-DYNA to verify the created card. On the basis of simple examples the participants will discuss the effect of numerical parameters, e.g. the influence of the time step size, on the resultant phase fractions. The scope of the workshop is to combine the theoretical background of modelling phase transformations with the experimental determination to obtain the necessary parameters for a numerical process simulation.

  • Introduction to the models for general phase change
  • Experimental determination of the phase transformation
  • Data preparation of dilatometer tests
  • Calculation of the transformation kinetics Example: 22MnB5
  • Fitting and verification of the material card (MAT_254)
  • Thermomechanical Forming Simulation