Plasticity and metal forming

lmapr2482  2019-2020  Louvain-la-Neuve

Plasticity and metal forming
Note from June 29, 2020
Although we do not yet know how long the social distancing related to the Covid-19 pandemic will last, and regardless of the changes that had to be made in the evaluation of the June 2020 session in relation to what is provided for in this learning unit description, new learnig unit evaluation methods may still be adopted by the teachers; details of these methods have been - or will be - communicated to the students by the teachers, as soon as possible.
5 credits
30.0 h + 22.5 h
Q2
Teacher(s)
Language
English
Main themes
• Macroscopic theory of plasticity
• Crystal and polycrystal plasticity
• Main plastic forming operations : rolling, extrusion, deep drawing, wire drawing, forging
• Formability
• Internal stress
• Contact mechanics
• Crystallographic textures
Aims
 At the end of this learning unit, the student is able to : 1 Contribution of the course to the program objectives According to the classification of LO in the EPL programme, this activity contributes to the development and acquisition of the following LO: LO1.1, LO1.2, LO1.3 LO2.1, LO2.2, LO2.4 LO5.3, 5.4, 5.6 Specific learning outcomes of the course At the end of this course, the student will be able to LO1.1. Explain the fundamental assumptions underlying several continuum plasticity theories (J2 deformation theory, yield surface, normality rule, J2 flow theory, anisotropic extensions, etc) and single crystal theory (e.g. Schmidt rule); LO1.1. Explain and identify the key technological and scientific issues in the most important forming operations: rolling, deep drawing, extrusion, wire drawing, forging. LO1.1. Describe how metal forming operations are affected by a few important phenomena including: plastic localization, damage, internal stresses, texture development, plastic anisotropy, contact and wear, high temperature microstructure evolution; LO1.2. and 1.3. Calculate, analytically, the evolution of stress and strain in plastically deforming samples/crystals under homogenous loading; LO1.2, 2.1, 2.2, 2.4. Use a commercial finite element code to simulate forming operations based on existing input files that can be modified to test different conditions/parameters; LO1.3, 2.2. Critically assess/compare numerical results to analytical model and make links with technological issues; LO5.3, 5.4, 5.6. Report (writing and oral) on a study based on finite element simulations of a forming operation involving a discussion on technological issues that can be addressed with the simulations and on the assessment of the analytical models.

The contribution of this Teaching Unit to the development and command of the skills and learning outcomes of the programme(s) can be accessed at the end of this sheet, in the section entitled “Programmes/courses offering this Teaching Unit”.
Content
Part I ' Plasticity theory
A.       Macroscopic theory in 1D
B.       Macroscopic theory in 3D (yield surface, J2 deformation theory, J2 flow theory, anistropic theory)
C.       Crystal plasticity theory
Part II ' Other phenomena during plastic forming operations
D.       Internal stress
E.       Crystallographic textures
F.       Formability
G.      Contact mechanics
H.      Microstructural evolution and high temperature deformation
I.         Évolutions microstructurales et déformation à chaud
Part III ' Main plastic forming operations
Teaching methods
Ex-cathedra lectures are given to present the plasticity theories as well as the additional scientific aspects essential in metal forming operations (plastic localization, damage, internal stress, texture, contact and wear, high temperature microstructure evolution). 7 to 8 sessions are organized during which students can solve exercises with the support of an assistant. The rest of the time is devoted to the project which starts with a presentation of the use of the finite element code. Each group is helped by a dedicated assistant. The students can use Abaqus teaching licences to run simulations and analyze the results, with access to a computer room.
Evaluation methods
The students will be individually graded based on the objectives indicated above. More precisely, the evaluation involves the grading of
• a project, by groups of 3 or 4 students, based on the use of the finite element code Abaqus to simulate a forming process under different operating conditions. The forming operation will be orally presented to the rest of the class, illustrated by the results of the finite element simulations. The oral presentation will be supplemented by a written report. The grading will account also for daily work during the semester.
• a set of imposed exercises the day of the written exam
• the answers to one or two theoretical questions selected within a list of about 10 questions of synthesis provided by the teachers during the year.
Other information
This course requires sufficient solid mechanics background (continuum mechanics and elasticity theory) and basic knowledge about mechanical properties of materials (notions of strength, ductility, hardening).
Online resources
Bibliography
Un syllabus rédigé en anglais par les enseignants.
Faculty or entity

Programmes / formations proposant cette unité d'enseignement (UE)

Title of the programme
Sigle
Credits
Prerequisites
Aims
Master [120] in Mechanical Engineering

Master [120] in Physical Engineering

Master [120] in Civil Engineering

Master [120] in Electro-mechanical Engineering

Master [120] in Chemical and Materials Engineering