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Numerical modeling of the structural behavior of thin-walled cast magnesium components using a through-process approach

Identifieur interne : 002A82 ( Main/Exploration ); précédent : 002A81; suivant : 002A83

Numerical modeling of the structural behavior of thin-walled cast magnesium components using a through-process approach

Auteurs : C. D Rum [Norvège] ; O. S. Hopperstad [Norvège] ; M. Langseth [Norvège] ; O.-G. Lademo ; S. Sannes

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Abstract

A through-process methodology for numerical simulations of the structural behavior of thin-walled cast magnesium components is presented. The methodology consists of casting process simulations using MAGMAsoft, mapping of data from the process simulation onto a FE-mesh (shell elements) and numerical simulations using the explicit FE-code LS-DYNA. In this work, generic High Pressure Die Cast (HPDC) AM60 components have been studied using 3-point bending and 4-point bending tests. The experimental data are applied to obtain a validated methodology for finite element modeling of thin-walled cast components subjected to quasi-static loading. The cast magnesium alloy is modeled using a user-defined material model consisting of an elastic-plastic model based on a non-associated J2-flow theory and the Cockcroft-Latham fracture criterion. The fracture criterion is coupled with an element erosion algorithm available in LS-DYNA. The constitutive model and fracture criterion are calibrated both with data from material tests and data from the process simulation using MAGMAsoft.


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<term>Associated plasticity</term>
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<term>Cast alloy</term>
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<term>Constitutive equation</term>
<term>Elastoplasticity</term>
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<term>Finite element method</term>
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<term>Material testing</term>
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<term>Paroi mince</term>
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<term>Haute pression</term>
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<term>Elastoplasticité</term>
<term>Inélasticité</term>
<term>Plasticité non associée</term>
<term>Plasticité associée</term>
<term>Erosion</term>
<term>Analyse structurale</term>
<term>Magnésium alliage</term>
<term>Charge statique</term>
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<term>Modélisation</term>
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<term>Théorie quasi statique</term>
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<div type="abstract" xml:lang="en">A through-process methodology for numerical simulations of the structural behavior of thin-walled cast magnesium components is presented. The methodology consists of casting process simulations using MAGMAsoft, mapping of data from the process simulation onto a FE-mesh (shell elements) and numerical simulations using the explicit FE-code LS-DYNA. In this work, generic High Pressure Die Cast (HPDC) AM60 components have been studied using 3-point bending and 4-point bending tests. The experimental data are applied to obtain a validated methodology for finite element modeling of thin-walled cast components subjected to quasi-static loading. The cast magnesium alloy is modeled using a user-defined material model consisting of an elastic-plastic model based on a non-associated J2-flow theory and the Cockcroft-Latham fracture criterion. The fracture criterion is coupled with an element erosion algorithm available in LS-DYNA. The constitutive model and fracture criterion are calibrated both with data from material tests and data from the process simulation using MAGMAsoft.</div>
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