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Abstract

The paper presents the results of work leading to the construction of a spatial hybrid model based on finite element (FE) and Monte Carlo (MC) methods allowing the computer simulation of physical phenomena accompanying the steel sample testing at temperatures that are characteristic for soft-reduction process. The proposed solution includes local density variations at the level of mechanical solution (the incompressibility condition was replaced with the condition of mass conservation), and at the same time simulates the grain growth in a comprehensive resistance heating process combined with a local remelting followed by free/controlled cooling of the sample tested. Simulation of grain growth in the entire computing domain would not be possible without the support of GPU processors. There was a 59-fold increase in the computing speed on the GPU compared to single-threaded computing on the CPU. The study was complemented by examples of experimental and computer simulation results, showing the correctness of the adopted model assumptions.
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Authors and Affiliations

Marcin Hojny
Tomasz Dębiński
ORCID: ORCID

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Abstract

The article presents the use of computer graphics methods and computational geometry for the analysis on changes of geometrical parameters for a mixed zone in resistance-heated samples. To perform the physical simulation series of resistance heating process, the Gleeble 3800 physical simulator, located in the Institute for Ferrous Metallurgy in Gliwice, was used. The paper presents a description of the test stand and the method for performing the experiment. The numerical model is based on the Fourier-Kirchoff differential equation for unsteady heat flow with an internal volumetric heat source. In the case of direct heating of the sample, geometrical parameters of the remelting zone change rapidly. The described methodology of using shape descriptors to characterise the studied zone during the process allows to parametrise the heat influence zones. The shape descriptors were used for the chosen for characteristic timing steps of the simulation, which allowed the authors to describe the changes of the studied parameters as a function of temperature. Additionally, to determine the impact of external factors, the remelting zone parameters were estimated for two types of grips holding the sample, so-called hot grips of a shorter contact area with the sample, and so-called cold grips. Based on the collected data, conclusions were drawn on the impact of the process parameters on the localisation and shape of the mushy zone.

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Authors and Affiliations

Tomasz Dębiński
ORCID: ORCID
Marcin Hojny
M. Głowacki
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Abstract

This paper presents practical capabilities of a system for ceramic mould quality forecasting implemented in an industrial plant (foundry). The main assumption of the developed solution is the possibility of eliminating a faulty mould from a production line just before the casting operation. It allows relative savings to be achieved, and faulty moulds, and thus faulty castings occurrence in the production cycle to be minimized. The numerical computing module (the DEFFEM 3D package), based on the smoothed particle hydrodynamics (SPH) is one of key solutions of the system implemented. Due to very long computing times, the developed numerical module cannot be effectively used to carry out multi-variant simulations of mould filling and solidification of castings. To utilize the benefits from application of the CUDA architecture to improve the computing effectiveness, the most time consuming procedure of looking for neighbours was parallelized (cell-linked list method). The study is complemented by examples of results of performance tests and their analysis.

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Authors and Affiliations

Marcin Hojny
K. Żaba
Tomasz Dębiński
ORCID: ORCID
J. Porada
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Abstract

The microalloying elements such as Nb, V are added to control the microstructure and mechanical properties of microalloyed (HSLA) steels. High chemical affinity of these elements for interstitials (N, C) results in precipitation of binary compound, nitrides and carbides and products of their mutual solubility – carbonitrides. The chemical composition of austenite, as well as the content and geometric parameters of undissolved precipitates inhibiting the growth of austenite grains is important for predicting the microstructure, and thus the mechanical properties of the material. Proper selection of the chemical composition of the steel makes it possible to achieve the required properties of the steel at the lowest possible manufacturing cost. The developed numerical model of carbonitrides precipitation process was used to simulate and predict the mechanical properties of HSLA steels. The effect of Nb and V content to change the yield strength of these steels was described. Some comparison with literature was done.
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Bibliography

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Authors and Affiliations

Przemysław Marynowski
1
ORCID: ORCID
Marcin Hojny
1
Tomasz Dębiński
1
ORCID: ORCID

  1. AGH University of Krakow, Poland
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Abstract

The paper reports the results of work leading to the construction of a spatial thermo-mechanical model based on the finite element method allowing the computer simulation of physical phenomena accompanying the steel sample testing at temperatures that are characteristic for the soft-reduction process. The proposed numerical model is based upon a rigid-plastic solution for the prediction of stress and strain fields, and the Fourier-Kirchhoff equation for the prediction of temperature fields. The mushy zone that forms within the sample volume is characterized by a variable density during solidification with simultaneous deformation. In this case, the incompressibilitycondition applied in the classic rigid-plastic solution becomes inadequate. Therefore, in the presented solution, a modified operator equation in the optimized power functional was applied, which takes into account local density changes at the mechanical model level (the incompressibility condition was replaced with the condition of mass conservation). The study was supplemented withexamples of numerical and experimental simulation results, indicating that the proposed model conditions, assumptions, and numerical models are correct.
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Bibliography

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Authors and Affiliations

Marcin Hojny
Tomasz Dębiński
ORCID: ORCID
M. Głowacki
1
Trang Thi Thu Nguyen
1

  1. AGH University of Science and Technology, Cracow, Poland
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Abstract

This paper identifies and describes the parameters of a numerical model generating the microstructure in the integrated heating-remelting-cooling process of steel specimens. The numerical model allows the heating-remelting-cooling process to be simulated comprehensively. The model is based on the Monte Carlo (MC) method and the finite element method (FEM), and works within the entire volume of the steel sample, contrary to previous studies, in which calculations were carried out for selected, relatively small areas. Experimental studies constituting the basis for the identification and description of model parameters such as: probability function, initial number of orientations, number of cells and number of MC steps were carried out using the Gleeble 3800 thermo-mechanical simulator. The use of GPU capabilities improved the performance of the numerical model and significantly reduced the simulation time. Thanks to the significant acceleration of simulation times, it became possible to comprehensively implement a numerical model of the heating-transformation-cooling process in the entire volume of the test sample. The paper is supplemented by results of performance tests of the numerical model and results of simulation tests.
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Authors and Affiliations

Marcin Hojny
Przemysław Marynowski
ORCID: ORCID
Tomasz Dębiński
ORCID: ORCID
D. Cedzidło
1
ORCID: ORCID

  1. AGH University of Science and Technology, Poland

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