Abstract
Solid-state processing of metal material is a very complex physical and chemical process, which is coupled by a series of variations including heat transfer, momentum transfer, mass transfer, and phase change. Applying three-dimensional (3D) finite element numerical method to the simulation of solid-state processing can perform analysis of metal material’s forging processes before production trial production, can obtain their relevant information such as material flow law, temperature field, and strain field under the minimum physical test conditions, thereby predicting metal material’s forming defects and improving their forging quality. On the basis of summarizing and analyzing previous research works, this paper expounded the current status and significance of solid-state processing of metal materials, elaborated the development background, current status, and future challenges of 3D finite element numerical simulation, introduced the discrimination method and free surface solution method of numerical simulation calculation, conducted finite element model’s geometric assumptions, material selection, element division, model establishment, parameter selection, and initial and boundary condition determination, and simulated and analyzed rheological casting, remelting heating, thixoforming, and rotary piercing processes of metal materials. The results show that the 3D finite element numerical method can not only simulate various processes of flow field, temperature field, stress field, and microstructure in solid-state processing but also can provide a reliable basis for effectively obtaining a reasonable description and finding a more optimized design plan for metal material processing in a short time, which plays an important role in understanding and analyzing solid metal forming process, controlling and optimizing process parameters, guiding and mastering rheological casting, and secondary heating and rotary piercing of metal materials.
Highlights
Solid-state processing of metal material is a very complex physical and chemical process, which is coupled by a series of variations including heat transfer, momentum transfer, mass transfer, and phase change. e simulation of temperature field and strain field in the solid-state processing of metal materials is to simulate the process of metal transforming from liquid to solid from the perspective of heat transfer, and the numerical solution of the thermal differential equation is obtained in the presence of phase change [1]
Solid-state processing of metal material refers to the deformability that a material can achieve without damage during plastic processing and is an important indicator of the material’s bulk forming ability [3]
Rheological casting is a 3D heat conduction process, but the rheological casting used for solid-state processing of metal materials mainly prepares cylindrical billets, which is a symmetric problem. e differential equations for solving the thermal field problem of continuous casting semisolid cylindrical ingots can be written as follows: z raTx + zrbTy + z rcTz
Summary
Solid-state processing of metal material is a very complex physical and chemical process, which is coupled by a series of variations including heat transfer, momentum transfer, mass transfer, and phase change. e simulation of temperature field and strain field in the solid-state processing of metal materials is to simulate the process of metal transforming from liquid to solid from the perspective of heat transfer, and the numerical solution of the thermal differential equation is obtained in the presence of phase change [1]. Applying three-dimensional (3D) finite element numerical method to the simulation of solid-state processing can perform analysis of metal material’s forging processes before production trial production, can obtain their relevant information such as material flow law, temperature field, and strain field under the minimum physical test conditions, and thereby predicting metal material’s forming defects and improving their forging quality [5]. On the basis of summarizing and analyzing previous research works, this paper expounded the current status and significance of solid-state processing of metal materials, elaborated the development background, current status, and future challenges of 3D finite element numerical simulation, introduced the discrimination method and free-surface solution method of numerical simulation calculation, conducted finite element model’s geometric assumptions, material selection, element division, model establishment, parameter selection, and initial and boundary condition determination, and simulated and analyzed rheological casting, remelting heating, thixoforming, and rotary piercing processes of metal materials.
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