Numerical Modelling and Development of New Technical Solutions in Metallurgy and Material Processing

Abstract

There have been no breakthroughs in ferrous metallurgy for the last 80 years. Automation and digitalization arrived, while the actual steel making processes saw almost no changes. Today, almost all industries experience rapid changes. In 2018 we will see a launch of trains that can travel as fast as1,200 km/h. In 2022 we will see aircrafts capable of flying from London to New York in 1 hour. They already know how to grow human arms and legs. And driverless taxis have become extremely popular. Should we be expecting to see a major breakthrough in metallurgy any time soon? In this paper you will learn about this and other problems, as well as possible ways to solve them. Also, the paper focuses on the results of the development of theory, mathematical models and novel processes, which were helpful in the forming of the ultra-high strength materials by combining the conventional methods of forming such as stamping, plate rolling, plastic bending and asymmetrical rolling. The ultimate aim was to manufacture parts having complex geometries of ultra-high strength sheets. Metalworking techniques like asymmetrical rolling gave rise to very high shear strains and it was used for increasing the strength of the materials. The addition of the incremental sheet forming to the varied combinations of conventional forming processes was used for increasing in the flexibility of the manufacturing process for ultra-high strength. The results of the research project were also encompassing numerical simulation and experimental investigations of the combined process accompanied by the development of the theoretical models for the same.