GOALI: A Computational-Experimental Program for Multiple Scale Fracture Simulation and Design of Metal Forming Processes

该学术联络机会（GOALI）项目将涉及美国铝业公司技术中心（ATC）的首席研究员和研究人员。该奖项旨在建立一个旨在提高生产率和产品质量的综合实验-计算研究计划。这将通过开发先进的多尺度计算模型和软件来模拟材料加工和后续工艺设计中的故障来完成。它将增加ATC的两个新发起的推力领域：(1)了解合金组织和工艺参数对冷轧过程中边缘开裂的影响；(2)提高切边质量，减少分切等材料剪切过程中的毛刺和碎屑。此外，与科学成形技术公司（SFTC）和俄亥俄超级计算机中心的合作将把模拟软件提升到解决复杂工业问题所需的高性能计算的先进水平。经过实验验证的多尺度计算机模型将引入自适应多层次层次，并从定量金相学中表达材料微观结构的细节，以模拟韧性断裂。计算模块的自适应多级系统将同时预测工件尺度上的变量，并将局部化和韧性断裂作为一种跨尺度损伤发生、相互作用和传播的现象进行建模。具有不同分辨率的计算子域的自适应层次结构将区分非关键区域和不断发展的关键区域，并将在纯微观模拟的“破坏性热点”上放大。实际微观结构的微观应力和损伤分析将由专门开发的Voronoi细胞有限元模型来完成。成形模拟将与设计方法和软件相结合，以预测“最佳”微观组织构成和工艺参数。将进行变形加工中的局部化和失效实验，包括缺口试样的载荷位移和断裂韧性数据的力学测试，以及冷轧和钣金剪切等实际过程

This Grant Opportunity for Academic Liaison with Industry (GOALI) project will involve the principal investigator and researchers at the ALCOA Technical Center (ATC). This award is to institute an integrated experimental-computational research program targeted at improving productivity and product quality. This will be accomplished by developing advanced multiple scale computational models and software for simulating failure in materials processing and subsequent process design. It will augment two newly initiated thrust areas at ATC on: (1) understanding the effect alloy microstructure and process parameters on edge cracking in cold rolling processes; and (2) improving cut-edge quality and minimize burr and debris in material shearing processes such as slitting. Furthermore, collaborations with Scientific Forming Technologies Corporation (SFTC) and Ohio Supercomputer center will elevate the simulation software to the advanced level of high performance computing needed for solving complex industrial problems.Experimentally motivated-validated, multi-scale computer models will introduce adaptive multi-level hierarchy and represent details of material microstructure from quantitative metallography, to simulate ductile fracture. The adaptive multi-level system of computational modules will concurrently predict variables at the scales of the work-piece and model localization and ductile fracture as a phenomenon of incidence, interaction and propagation of damage across the scales. Adaptive hierarchy of computational sub-domains with varying resolutions will differentiate between non-critical and evolving critical regions and will zoom in at 'damaging hotspots' for pure microscopic simulations. Microscopic stress and damage analysis of real microstructures will be done by the specially developed Voronoi cell finite element models. The forming simulations will be coupled with design methodologies and software to predict 'optimal' microstructural constitution and process parameters. Experiments on localization and failure in deformation processing will be performed, and will include mechanical testing of notched specimens for load-displacement and fracture toughness data, and real process like cold rolling and sheet metal shearing for