11 Juillet – Thesis defense - Diego Luiz Britez Gonzalez

14 h Amphi La Rochefoucauld (ENSAM Talence)

A forming process modeling integrating the interaction between processes in the material behavior.

The current industrial context requires the optimization of production resources, particularly raw materials and energy consumption. This commitment does not only meet the criteria of competitiveness related to production costs but also to the environmental impact of the overall manufacturing process. To solve this problem, is required a mode to define optimization strategies through a complete forming process during a mechanical part manufacturing.
Most behavior laws used for metals, dedicated to perform simulations of forming and machining processes are characterized by an isotropic behavior.  These models are effective in predicting the behavior under proportional loading, but by definition cannot consider the anisotropy developed during work hardening. This limitation makes it impossible to take to consider the interaction effects between the different stages of the manufacturing process. This work goes through the phenomenological behavior laws capable of modeling this phenomenon, in order to obtain an accurate model of the overall process. Knowing that the modeling of each process stage requires a solver and specific definitions, a methodology as well as numerical tools necessary to manage the hardening variables along the process have been developed. This methodology allows a traceability of the values of hardening variables throughout the simulation of the process, dividing the global simulation,  admitting the use of different solvers or software.
This work explores the profile estimation obtained with destructive  residual stresses measurement  methods in order to compare simulation results with experiments. A new methodology using inverse analysis is developed and implemented. From  numerical generated data, the new method is applied and compared with two destructive reference methods. The results in this application show, a decrease in both the error and the uncertainty level.

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