Ideal Process Design Approach for Hot Metal Working

..................................................................................................................... iv ACKNOWLEDGEMENTS ............................................................................................ vi LIST OF FIGURES ......................................................................................................... ix LIST OF TABLES ........................................................................................................... xi NOMENCLATURES ..................................................................................................... xii CHAPTER I: INTRODUCTION ............................................................................................................ 1 1.1 Challenges of Process Design .............................................................................................. 1 1.2 Design Process Relationships .............................................................................................. 3 1.3 Objective ............................................................................................................................... 5 CHAPTER II: APPROACH ...................................................................................................................... 6 2.1 Overall Systems Approach for Ideal Process Design ........................................................ 6 2.2 Ideal Material System Behavior ......................................................................................... 7 2.3 Ideal Deformation Process System Behavior ..................................................................... 9 2.4 Ideal Equipment System Behavior ................................................................................... 10 2.5 Illustration of Ideal Process Design Approach Using Hot Metal Rolling Process........ 12 CHAPTER III: DETERMINISTIC MATERIAL BEHAVIOR FOR IDEAL PROCESS DESIGN . 15 3.1 Dynamic Material Model Stability Criteria .................................................................... 16 3.2 Activation Energy Analysis for Identifying Desirable Mechanism ............................... 20 viii 3.3 Sensitivity Analysis for Robust Process Design ............................................................... 22 3.4 Summary ............................................................................................................................. 23 CHAPTER IV: IDEAL FORMING THEORY AND SIMPLIFYING ASSUMPTIONS FOR IDEAL PROCESS DESIGN ........................................................................................................ 25 4.1 Ideal Forming Principles ................................................................................................... 26 4.2 Simplifying Assumptions for Ideal Process Design ......................................................... 27 4.3 Summary ............................................................................................................................. 29 CHAPTER V: OPEN LOOP CONTROL SYSTEM FOR IDEAL PROCESS DESIGN ................. 30 5.1 Open Loop vs. Close Loop ................................................................................................. 30 5.2 Summary ............................................................................................................................. 32 CHAPTER VI: APPROACH ILLUSTRATION THROUGH CASE STUDY .................................... 34 6.1 Case Study: Steel Hot Rolling Process Designed by Ideal Process Design Approach . 35 6.2 Example: Design of Hot Rolling Process for Producing Steel Sheets with Desired Microstructure ......................................................................................................................... 41 CHAPTER VII: CONCLUSION ............................................................................................................... 44 REFERENCES ................................................................................................................ 45 APPENDIX A: MICROSTRUCTURE EVOLUTION MODELS FOR HOT WORKING ............... 49 APPENDIX B: AXIOMATIC APPROACH FOR PROCESS DESIGN ............................................. 57