Integrated Optimization of Melting, Casting and Plastic Working for Metals and Metallic Alloys

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In the modern or near-future steel making and processing systems, such elemental technologies as melting, casting or plastic forming are fusioned and integrated into new powerful processing systems which could grow coming bases of fabrication in next century. The melting forging or the forging of mushy-state metal alloys are typical technology of plasticity where both casting and forging technologies are combined into new processing. The mechanical alloying or explosive forming are identified as new confusions where melting processings and plastic working are integrated into new faces. In the present study, researchers are concerned with understanding the fundamental characteristic features and frame of methodology for conceptual and detail designs of new promising processings in the integration of melting, casting and plastic working and describing the integrated optimization for these processes. With respect to the optimization of melting and casting, new computational model is propo … More sed and developed : quad-tree/modified quad-tree model is proposed and fully utilized to enable us to make set or boolean operation to deal with the complex shaped casting. Our developing prototype system has demonstrated the validity and effectiveness of our approach. Since three dimensional behaviors become or will grow an essential issue in the rolling technology, new frame of rolling analysis have been developed to deal with the actual three dimensional rolling behaviors even for complex shape rolling systems ; our developing deformation-mode method provides the fundamental tool to evaluate the work profiles in flat rolling and to predict the change of figures in shape rolling. This method can be easily connected with the heat transfer analysis by the boundary element method to take into account the mutual interaction between deformation of works and heat transfer/temperature distribution in works. Through the uniaxial tensile testing in the elevated temperature with the controlled history of temperature and the programmed loading conditions for steel or Ni, we have understood the fundamental properties and responses in the relatively wide range of temperature where these materials lose their ductility ; these studies lead to profound understanding of various mechanisms appearing in the process metallurgy. The above researches provide a basis to construct new fusioned and integrated processing. Less