Cellular automata model for prediction of crack initiation and propagation in hot forging tools

Abstract The paper presents design and implementation of the cellular automata (CA) model, which predicts damage of forging tools due to fatigue. The transition rules for the model were developed on the basis of known information regarding crack initiation and propagation. The coefficients in the model were determined by the inverse analysis of the thermal fatigue tests performed on the Gleeble 3800 simulator and in the special device with a rotating disc. The CA model was coupled with the conventional abrasive wear model. The layers of cell in the CA space, which are in contact with the workpiece, were removed successively following the abrasive wear of the tool. The CA model was connected with the finite element (FE) programme, which simulates stresses in tools during forging. Since this multiscale approach appeared to be extremely demanding as far as computing times are considered, an efficient implementation of the model on heterogeneous hardware architectures was prepared. Results of simulations were compared with the industrial data and good predictive capabilities of the model were confirmed.

[1]  Bernd-Arno Behrens,et al.  Numerical and Experimental Investigations on the Service Life Estimation for Hot-Forging Dies , 2012 .

[2]  Barrau Olivier,et al.  Investigations of friction and wear mechanisms of hot forging tool steels , 2002 .

[3]  K. Nowak.  Micro- versus macro- modelling of creep damage , 2009 .

[4]  Lukasz Madej,et al.  Numerical Modelling of Fracture Based on Coupled Cellular Automata Finite Element Approach , 2014, ACRI.

[5]  A. Gurson.  Continuum Theory of Ductile Rupture by Void Nucleation and Growth: Part I—Yield Criteria and Flow Rules for Porous Ductile Media , 1977 .

[6]  J. Chaboche.  Continuum Damage Mechanics: Part II—Damage Growth, Crack Initiation, and Crack Growth , 1988 .

[7]  Mats Oldenburg,et al.  Effect of temperature on friction and wear of prehardened tool steel during sliding against 22MnB5 steel , 2013 .

[8]  Yohng-Jo Kim,et al.  A study on life estimation of hot forging die , 2009 .

[9]  Trevor A. Dean,et al.  Effects of surface treatments and lubricants for warm forging die life , 2001 .

[10]  Propozycja wykorzystania automatów komórkowych do modelowania inicjacji i propagacji pęknięć w wyniku zmęczenia cieplnego , 2013 .

[11]  Łukasz Rauch,et al.  Efficient cellular automata model for prediction of damage of hot forging tools due to thermal fatigue , 2014 .

[12]  Katia Mocellin,et al.  Numerical life prediction of mechanical fatigue for hot forging tools , 2009 .

[13]  Thomas Seelig,et al.  Fracture Mechanics: With an Introduction to Micromechanics , 2006 .

[14]  Y. E. Kim,et al.  A study on the influence of the seat and head restraint foam stiffnesses on neck injury in low speed offset rear impacts , 2009 .

[15]  S. Fréour,et al.  A multi-scale analysis of local stresses development during the cure of a composite tooling material , 2013 .

[16]  Jean Lemaitre,et al.  Local approach of fracture , 1986 .

[17]  Siamak Abachi,et al.  Wear analysis of hot forging dies , 2010 .

[18]  Sören Andersson,et al.  Simulating sliding wear with finite element method , 1999 .

[19]  Thomas Ørts Pedersen,et al.  Numerical modelling of cyclic plasticity and fatigue damage in cold-forging tools , 2000 .

[20]  I. Park,et al.  A Study on Die Wear Model considering Thermal Softening(II) -Application of Suggested Wear Model , 1999 .

[21]  Yong-Taek Im,et al.  TOOL LIFE PREDICTION FOR THE BOLT FORMING PROCESS , 2007 .

[22]  Y. Shibutani.  MESOSCOPIC DYNAMICS ON DISLOCATION PATTERNING IN FATIGUED MATERIAL BY CELLULAR AUTOMATA(Special Issue on Hierarchical Estimations of Materials Strength) , 1999 .

[23]  S. Ziółkiewicz,et al.  Modeling of the tool wear in TR forging of fastener , 2013 .

[24]  J. Archard.  Contact and Rubbing of Flat Surfaces , 1953 .

[25]  Z. Gronostajski,et al.  A review of the degradation mechanisms of the hot forging tools , 2014 .

[26]  Raymond Bayer,et al.  Mechanical wear fundamentals and testing , 2004 .

[27]  M. Pietrzyk,et al.  Modelling of the die wear in the hot forging process using the Archard model , 2015 .

[28]  Marian Marciniak,et al.  Numerical modelling of the thermal fatigue of steel WCLV used for hot forging dies , 2013 .

[29]  Irina Goryacheva.  Multiscale Modelling in Contact Mechanics , 2009 .

[30]  Tadej Muhič,et al.  Analysis of the main types of damage on a pair of industrial dies for hot forging car steering mechanisms , 2011 .

[31]  S. Kang,et al.  A Study on Die Wear Model considering Thermal Softening(I) -Construction of Wear Model , 1999 .