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Lecture-1 Introduction

The document discusses the simulation of processes in laser surface hardening and roll twist delivery guides, focusing on the influence of input parameters on hardness distribution and forces acting on delivery guides. It outlines methods for estimating optimal input parameters, governing equations, and the effects of wear on performance. Additionally, it covers structural analysis and design considerations for mechanical systems, emphasizing the importance of simulations in optimizing processes and materials.

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raja
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1 views

Lecture-1 Introduction

The document discusses the simulation of processes in laser surface hardening and roll twist delivery guides, focusing on the influence of input parameters on hardness distribution and forces acting on delivery guides. It outlines methods for estimating optimal input parameters, governing equations, and the effects of wear on performance. Additionally, it covers structural analysis and design considerations for mechanical systems, emphasizing the importance of simulations in optimizing processes and materials.

Uploaded by

raja
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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WHY SIMULATE PROCESSES?

Case Study: Laser Surface Hardening


Working Principle

Heating to above Austenizing temperature and rapid self cooling results in formation of hard martensitic
phase on outer layer
Thickness Hardness Distribution

Laser surface heat treatment can be used to harden material up to around 1 mm depth
Input Parameters and Outcome

Input Process Parameters:

● Laser power
● Laser spot diameter What the input parameters influence:
● Laser power profile (flat top, gaussian, etc.)
● Scan speed ● Hardness depth
● In-plane hardness profile
Material Parameters: ● Thermal stress distribution

● Equivalent carbon percentage (to estimate


austenizing temperature, desired cooling rate etc.)
How to Estimate Optimal Input Parameters?
Interpret the results and derive
Consider a relevant
input parameters that provide
domain
desired output

Subject the domain to relevant


conservation laws, e.g. energy Solve for relevant field variables,
conservation, momentum e.g. temperature, displacement,
conservation, etc. stresses, etc.

Ensure that relevant material Apply relevant initial and


laws are satisfied, e.g. Fourier boundary conditions, e.g.
law of heat conduction, linear uniform temperature and time
elasticity, isotropic plasticity, etc. varying heat flux input
Governing PDEs, BCs, and Initial Conditions
q
Energy Conservation:

Fourier Law of Heat Conduction:

Material

1D Heat Conduction Equation:

Initial, Boundary Conditions:


t0 = d/V

t
Solution to the Problem for Small Time

With
Solution to the Problem for Small Time

x=0

x=1 mm

Solution for 1.5 kW laser power, 10 mm spot diameter, 1500 mm/min scan speed,
50 W/mK thermal conductivity and 2.3x10-5 m2/s diffusivity
Process Monitoring of Roll
Twist Delivery Guides

by

Prof. Vikranth Racherla


&

Mr. Venkata Dilip


Bar Rolling: Role of Roll Twist Delivery Guide

Bar stock with elliptical cross-section needs to be rotated by 90


degrees before it is fed to the rollers in the next stand
Roll Twist Delivery Guide: Process Parameters

Worms shown in pink and green can be used to set the


orientation of roller and gap between the rollers
Objectives

• Obtain forces acting on RTD guides as a function of roller orientation,


stock temperature, and gap between supports and RTD guides
• Study the effect of wear on work rolls of previous stands on roll separating
forces
• Investigate the effect of wear on RTD guides on roll separating forces
• Suggest ways of instrumenting the roll twist delivery guides to monitor
wear of work rolls and detect any abnormalities in the process
Forces acting on RTD guides

Effective plastic strain


distribution for stock
at 800oC, rollers at
55o orientation, and
for 100 mm gap
between supports
and RTD guide rolls

Roll
separating Peak roll
force as a separating
function of force
time
Effect of Parameters on Thrust and Roll Separating
Forces in RTD Guides

Peak roll
separating
forces at 900
and 1000
degrees
stock
temperature

Peak thrust
forces at 900
and 1000
degrees
stock
temperature
Full Scale Simulation Results
Effect of RTD and Work Roll Wear

Effect of roll twist delivery guide and work roll wear on


roll separating forces on RTD guides
Structural Analysis: Euler Bernoulli Beam Elements

Trommels used for “sieving” in


mining, power plants, etc.

Inputs: Load Analysis Output Variables: Commercial objective: Keep the structure light
distribution, end Displacements, natural weight, yet sturdy enough to meet the
conditions, length, frequencies, stress requirement. Lower weight means lower material
diameter distribution, failure loads, cost, lower transportation cost, and easier
fatigue life handling and better sale due to lower prices
Design and Analyses of Mechanical Systems

α = 200 α = 370
Rpc = 6 mm Rpc = 3 mm
Rdc = 30 mm Rdc = 30 mm
t0 = 1.6 mm t0 = 1.4 mm

Design and analyses of cradles for carrying steel Optimization of punch and die geometries in tractrix
rope bundles on ships for Usha Martin Ltd., Kolkata die forming
Experiments and Simulations of Laser Forming

Bowl shaped laser


forming
Course Content
Introduce boundary element
Solve 1D steady-state problems
method and solve a few
using variational methods
problems using this method

Learn about calculus of


variations, Euler equation, Solve single variable problems in
natural and essential BCs, and 2D using finite element method
Hamiltonian principle

Introduce finite element method, Solve eigenvalue and time


and solve 2nd order and 4th dependent problems in 1D
order differential eqs. in 1D using using finite element method
finite element method
Euler Bernoulli Beams: Governing Equations, Material Models,
Boundary Conditions, and Initial Conditions

Governing Equation:

Net normal force acting per unit length of the


beam is zero

Material Model:
Moment is directly proportional to curvature
at the beam location. Bending stiffness is EI.

Boundary Conditions:

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