Abstract
This work shows a sequence of numerical models for the simulation of the Presta joining process: a well-established industrial process for manufacturing assembled camshafts. The operation is divided into two sub-steps: the rolling of the shaft to widen the cam seat and the joining of the cam onto the shaft. When manufactured, the connection is tested randomly by loading it with a static torque. Subsequently, there are three numerical models using the finite element method. Additionally, a material model of finite strain viscoplasticity with nonlinear kinematic hardening is used throughout the whole simulation process, which allows a realistic representation of the material behavior even for large deformations. In addition, it enables a transfer of the deformation history and of the internal stresses between different submodels. This work also shows the required parameter identification and the associated material tests. After comparing the numerical results with experimental studies of the manufacturing process for steel-steel connections, the models are used to extend the joining process to the utilization of aluminum shafts.
Highlights
In materials science and continuum mechanics, research is done on the development of complex constitutive models that are able to reproduce the elastic-viscoplastic material behavior of metals at large deformations
A phenomenological material model of finite strain viscoplasticity with nonlinear kinematic hardening introduced by Shutov and Kreißig [1] is applied to an industrial multi-stage manufacturing process: the Presta joining process (PJP)
The phenomenological material model of finite strain viscoplasticity with nonlinear kinematic hardening introduced by Shutov and Kreißig [1] has been extended to a formulation providing multiple backstresses in Shutov et al [7] (Figure 2)
Summary
In materials science and continuum mechanics, research is done on the development of complex constitutive models that are able to reproduce the elastic-viscoplastic material behavior of metals at large deformations. There still is a lack of usage of those models in industrial applications, where detailed and complex simulation models are necessary, for example to analyze production processes and the resulting behavior of the produced structures. Numerically-efficient implementations of material models with high prediction accuracy and applicability in multi-stage forming processes are required. In this contribution, a phenomenological material model of finite strain viscoplasticity with nonlinear kinematic hardening introduced by Shutov and Kreißig [1] is applied to an industrial multi-stage manufacturing process: the Presta joining process (PJP).
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