vtt propertunetm environment - vtt technical … of the future... · · 2014-11-28fracture...
TRANSCRIPT
1 22/09/2014
VTT ProperTuneTM Environment
2 22/09/2014
MATERIAL DESIGN BY
COMPUTATIONAL MODELLING AND SIMULATION
3 22/09/2014
MULTISCALE MATERIAL MODELLING
4 22/09/2014
PSPP CHAIN MODEL IN
MATERIALS SCIENCE AND ENGINEERING
Olson, Science, 277 (1997) 1237-42
5 22/09/2014
(1) Top surface cracking
=> coating failure
High σtens = 3600 MPa
BL influence < 7%
(4) Substrate loading
=> substrate failure
High σcomp = 4200 MPa
BL influence < 6%
(3) Load carrying capacity
=> deflection, plow friction
High σcomp = 5600 MPa
BL influence < 8%
(2) Interface cracking
=> coating delamination
Rigid BL σtens = 5700 MPa
Elastic BL σtens = 1200 MPa
STRESSES AND STRAIN IN 2 μm TiN
CERAMIC COATING ON HIGH SPEED STEEL
k g h 3 c s .d s f 0 4 1 1 0 1
+ +
Diamond stylus
3 2 1Coating pulling
Interface sliding
Ploughing frictionfracture plastic deformation
6 22/09/2014
First Principal Stresses in a Composite WC/CoCr
Coating by Macro- and Micro FEM Modelling
7 22/09/2014
Metallic materials - Synthetic aggregates by 3D voxel manipulation
Introduction of twins (or
laths etc.) to a primary
structure
Use of 3D discrete voxel volumes for complete freedom in manipulating nano- and microstructures, to
obtain 3D images of structure. Emphasis in metallic and composite structures, but no morphological
limitations with respect to the method itself.
Isosurfaces (grain
boundaries) after stochastic
Monte-Carlo sampling of
grain boundaries (to
generate more realistically
shaped grains and
structures)
Introduction of 2nd
phase structures
(precipitates, carbides
etc) to a primary
structure
Synthetic
microstructure by
tesselation and
“filling”
Also, mixing of synthetic and imaging features (i.e. “pluck” features of imaging data)
8 22/09/2014
Real SEM and Image Analysis
Based Model
9 22/09/2014
Thermal spray coatings – Image based analysis
SEM image
detail
Segmentation
for phases
and defects
Meshing or
use of discrete
methods
Simulated
material test –
indentation
stress and
strain
distribution
local
material
distribution
stress contours strain contours
10 22/09/2014
Case study: Effect of carbide morphology, size,
clusters and MFP – imaging based (WC-CoCr)
11 22/09/2014
Multiscale modeling and material design for wear and friction
Wear and friction as a set of coupled multiscale problems having an impact on component performance ―
drive towards a permeating and tailored component specific solution.
wear during
component
lifetime,
effects of
microscale
topography
and surface
texture
nano-microstructures of
interfaces, transition and
gradient layers and their
behavior
substrate structure at nano-
and microstructural scales
tribochemistry and
lubrication, mechanisms
of friction and wear at
nanoscale
coating composite
structure at nano- and
microstructural scales
component scale wear and
tribology problem
ANL14.2.2013/Demapp confidential
12 22/09/2014
INTEGRATED MATERIAL MODELLING FOR DEMANDING APPLICATIONS – IMAGO
Å
μm
nm
mm
h ms μs ns fs ps s
CFE FEM
MDS
Scratch
test
FEM
Raman
CFE,MDS
Resid.
stress
CFE PoD
FEM
= model validation methods
Nano
indent
MDS AFM
MDS
FEM = Finite Element Method
CFE = Constrain Free Energy
MDS = Molecular Dynamic Simulation
In-situ
TEM scratch
MDS
13 22/09/2014
Continuum – meso scale software for
microstructural material modelling
1) Commercial software
2) Open source software
3) In-house software development (at all stages)
Abaqus Comsol
Matlab GiD
Warp3D Aster
Salome Scipy
Pp oof2
Gmsh qhull
Paraview pyMPl
Python Fortran C++
14 22/09/2014
What is actually in VTT ProperTune?
A collection of material modeling “tools” applied, incorporated and developed during the last 10-15 years, during the time when so
called “multiscale material modeling” has been taking off. A collection of software, interfaces and especially modeling libraries
enabling development of new complex-like models with “some sort of ease” without all proprietary limitations. Quite a bit of the
core from FP6-7 projects, recently from Demapp, ties to Imago and Multidesign.
15 22/09/2014
What is actually in VTT ProperTune?
DESICRI: multiscale
modeling of metallic
and MMC composite
materials
KYT: long
term life
assessment
of Cu-OFP
in geological
disposal
EEHYP:
coupling
fluid flow &
discrete
fracture in
pulping
HICONS:
complex contact
problems and
wear
CREATE:
phase field
methods for
coarse
graining
DMW: fracture
assessment of
multiphase
welds
PERFORM60:
coupling
atomistic and
continuous
plastic flow
IMAGO:
aging of
DLC
SAFIR:
fracture
assessment of
RPV
materials
SURVIVE:
crystal
plasticity and
fracture
models
One of the keys ideas has been to try to develop a flexible kit of tools, so exploitation of past work is efficient, new projects can
take on bigger challenges in a resource efficient manner (something about the wheel here)…… examples of quite differing
problems fitting under the same roof is quite common in modeling.
POLYFRIC:
erosion
wear of
elastomers
16 22/09/2014
VTT ProperTune™ Industrial References
The VTT ProperTune™ material multiscale modelling and simulation concept has been applied on the following industrial cases in the FIMECC DEMAPP programme: 1. Kone: Wear prediction of elevator mechanical systems 2. Konecranes: Lifing of industrial crane sheave-wire rope contact 3. Componenta: Wear resistance of cast iron components 4. Teknikum: Erosive wear in elastomer components 5. Metso Minerals: Impact wear in mining equipment 6. Ruukki: Wear mechanisms of wear resistant steels
17 22/09/2014
VTT ProperTune™ Industrial Reference
Kone: elevator mechanical systems
”High resolution mechanical and multiscale material models were developed for cast iron and coated components to predict wear, estimate lifetime and select optimal wear resistant materials.”
18 22/09/2014
VTT ProperTune™ Industrial Reference
Componenta: wear resistant components ”The wear resistance of cast iron and composite coatings was analysed and wear life optimised by multiscale material models for mechanical components in severe industrial conditions”
19 22/09/2014
VTT ProperTune™ Industrial Reference
Teknikum: elastomer components
”Multiscale material modelling and simulations was used for visualisation of erosive wear mechanisms and for optimising the material properties of elastomer components.”
20 22/09/2014
VTT ProperTune™ Industrial Reference
Ruukki: wear resistant steels
”The impact wear resistance of Raex and Ramor steels was analysed and wear life optimised by multiscale material modelling and simulation for use in severe industrial conditions ”