This document discusses designing novel heterogeneous thermomechanical tests using topology optimization. Standard material tests are expensive and time-consuming. The research aims to design tests that provide more information about material behavior from fewer experiments. This will be done using topology optimization to design test specimens that produce highly heterogeneous strain fields, along with digital image correlation to measure the fields. The work has so far used topology optimization within an elastic framework to optimize test geometries and loading. Future steps involve extending the optimization to non-linear materials and validating experiments on real specimens.
Design of novel heterogeneous thermomechanical tests using topology-based opt...Vform Xsteels
Nowadays, the development and design of new mechanical parts are performed using virtual manufacturing tools. For this purpose, numerical simulation software uses complex material constitutive models to reproduce real material behavior. However, the reliability of the simulation’s results is conditioned by the accuracy of the input data. The calibration of material models depends on a proper material characterization, which turns to be expensive due to the required large number of mechanical tests.
Design and validation of a heterogeneous interior notched specimen for materi...Vform Xsteels
Currently, virtual manufacturing and simulation predictions are crucial in the design and development of engineering parts. However, its reliability largely depends on the adopted constitutive model and accuracy of the governing material parameters. A complex and robust phenomenological constitutive model requires the calibration of many parameters. This is a very time-consuming task, particularly when using classical procedures, which involves many homogeneous mechanical experiments and high costs.
Recommendation engine and uncertainty techniques for the efficient calibratio...Vform Xsteels
Nowadays, digitalisation and virtualisation are the keys for companies’ success and competitiveness. Thus, numerical simulation tools are essential for engineering analysis and development. The success of a simulated material behaviour prediction depends on the chosen complex constitutive model and the correctness of its parameter identification. These days, it is used several classical mechanical tests to identify the model’s parameters.
Identification of orthotropic elastic properties of wood by a synthetic image...Vform Xsteels
This work aims to identify orthotropic linear elastic constitutive parameters of Pinus pinaster Ait. wood through the Finite Element Model Updating (FEMU) methodology. The approach is validated using both FE and synthetic image data. In the latter, digital image correlation is carried out on synthetic images deformed according to a 2D FE model. A systematic comparison is carried out. The identifiability for the four orthotropic material parameters on the radial-tangential (RT) plane is discussed regarding robustness and relative errors.
Experimental Investigation and Parametric Analysis of Surface Roughness in C...IJMER
The manufacturing industries are very much concerned about the quality of their products.
They are focused on producing high quality products in time at minimum cost. Surface finish is one of the
crucial performance parameters that have to be controlled within suitable limits for a particular process.
Surface roughness of machined components has received serious attention of Researchers for many years.
It has been an important design feature and quality measure in machining process. There are a large
number of parameters which affect the surface roughness. These include cutting tool variables, work
piece material variables, cutting conditions etc. Therefore, prediction or monitoring of the surface
roughness of machined components has been challenging and unexplored area of research
The present work is therefore in a direction to integrate effect of various parameters which effect the
surface roughness. Experiments were carried out with the help of factorial method of design of
experiment (DOE) approach to study the impact of turning parameters on the roughness of turned
surfaces. A mathematical model was formulated to predict the effect of machining parameters on surface
roughness of a machined work piece. Model was validated with the experimental data and the reported
data of other researchers. Further parametric investigations were carried out to predict the effect of
various parameters on the surface research
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Design of novel heterogeneous thermomechanical tests using topology-based opt...Vform Xsteels
Nowadays, the development and design of new mechanical parts are performed using virtual manufacturing tools. For this purpose, numerical simulation software uses complex material constitutive models to reproduce real material behavior. However, the reliability of the simulation’s results is conditioned by the accuracy of the input data. The calibration of material models depends on a proper material characterization, which turns to be expensive due to the required large number of mechanical tests.
Design and validation of a heterogeneous interior notched specimen for materi...Vform Xsteels
Currently, virtual manufacturing and simulation predictions are crucial in the design and development of engineering parts. However, its reliability largely depends on the adopted constitutive model and accuracy of the governing material parameters. A complex and robust phenomenological constitutive model requires the calibration of many parameters. This is a very time-consuming task, particularly when using classical procedures, which involves many homogeneous mechanical experiments and high costs.
Recommendation engine and uncertainty techniques for the efficient calibratio...Vform Xsteels
Nowadays, digitalisation and virtualisation are the keys for companies’ success and competitiveness. Thus, numerical simulation tools are essential for engineering analysis and development. The success of a simulated material behaviour prediction depends on the chosen complex constitutive model and the correctness of its parameter identification. These days, it is used several classical mechanical tests to identify the model’s parameters.
Identification of orthotropic elastic properties of wood by a synthetic image...Vform Xsteels
This work aims to identify orthotropic linear elastic constitutive parameters of Pinus pinaster Ait. wood through the Finite Element Model Updating (FEMU) methodology. The approach is validated using both FE and synthetic image data. In the latter, digital image correlation is carried out on synthetic images deformed according to a 2D FE model. A systematic comparison is carried out. The identifiability for the four orthotropic material parameters on the radial-tangential (RT) plane is discussed regarding robustness and relative errors.
Experimental Investigation and Parametric Analysis of Surface Roughness in C...IJMER
The manufacturing industries are very much concerned about the quality of their products.
They are focused on producing high quality products in time at minimum cost. Surface finish is one of the
crucial performance parameters that have to be controlled within suitable limits for a particular process.
Surface roughness of machined components has received serious attention of Researchers for many years.
It has been an important design feature and quality measure in machining process. There are a large
number of parameters which affect the surface roughness. These include cutting tool variables, work
piece material variables, cutting conditions etc. Therefore, prediction or monitoring of the surface
roughness of machined components has been challenging and unexplored area of research
The present work is therefore in a direction to integrate effect of various parameters which effect the
surface roughness. Experiments were carried out with the help of factorial method of design of
experiment (DOE) approach to study the impact of turning parameters on the roughness of turned
surfaces. A mathematical model was formulated to predict the effect of machining parameters on surface
roughness of a machined work piece. Model was validated with the experimental data and the reported
data of other researchers. Further parametric investigations were carried out to predict the effect of
various parameters on the surface research
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The traditional Z-Map was re-invented to a common data model for representation of geometry, attributes, physical states and other characteristics of novel manufacturing processes, which may include a multi-step operation of milling, turning, moulding and EDM (Electro-Discharge Machining), etc. The method is used to integrate these discrete point unit processes into a multi-step model for pervasive processes design and verification. A second patent has been filed to apply this method in mould design and verification.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
On the comparison of heterogeneous mechanical tests for sheet metal character...vformxsteels
IDDRG 2022
M. Gonçalves, M.G. Oliveira, S. Thuillier, A. Andrade-Campos
Centre for Mechanical Technology and Automation (TEMA),
Department of Mechanical Engineering
University of Aveiro, Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL
F-56100 Lorient, France
1
On the topology design of a mechanical heterogeneous specimen using geometric...vformxsteels
IDDRG 2022
M. Gonçalves, S. Thuillier, A. Andrade-Campos
Centre for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering,
University of Aveiro, Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
41st International Deep Drawing Research Group Conference, 6 - 10 June 2022, Lorient, France
On the topology design of an innovative heterogeneous mechanical test for mat...vformxsteels
RS 2022
On the topology design of an innovative
heterogeneous mechanical test for material
mechanical characterization
Centre for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering, University of Aveiro,
Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
Doctoral Program in Mechanical Engineering
On the topology design of an innovative heterogeneous mechanical test for mat...vformxsteels
RS2022
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
Centre for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering, University of Aveiro,
Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
1
A practical approach to eliminate defects in gravity die cast al alloy castin...eSAT Journals
Abstract
This paper deals with elimination of defects in aluminium alloy castings produced by gravity die casting process. The main intention of work is to investigate the defects and improve quality of a gravity die cast component using Computer Aided Casting Simulation Software. In this study an industrial gravity casting die is used which was producing defective components. The die and components produced by the die are studied to eliminate the defects using virtual simulations. The defects in the components are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons for the defects are analyzed as either improper selection of process parameters, or improper design of gating and risering system. SOLIDCast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. The work is carried out in two stages. In first stage, few test castings are produced by modifying the process parameters (pouring temperature, pouring time, pre heat and alloy type) and results are compared with simulation results produced using same parameters. The pouring and simulation results are observed to be in good accordance with each other. In second stage, number of virtual iterations of casting is performed by changing riser dimensions. It was found from the simulation results that riser with 35mm diameter is required to produce casting with zero defects. The die is modified accordingly with the simulation results and metal is poured. The castings produced are observed to be sound and contain no defects; and also it is verified that solidification simulation helps in locating the defects, eliminating them and ultimately improving the quality of castings without any shop-floor trails.
Keywords: Aluminum-Alloys, Casting Defects, Gravity Die Casting, Material Density and SOLIDCast Simulation
On the power of virtual experimentation in MT2.0: a VFORM-xSteels outlookvformxsteels
Sam Coppieters, A. Gil Andrade-Campos et al.
MatchID Global User Meeting
On the power of virtual experimentation in MT2.0 : a VFORM outlook
22 February2023 | Southampton, UK
Uncertainty quantification of inversely identified plastic material behavior ...vformxsteels
M Conde, S Coppieters, A Andrade-Campos
TEMA, Department of Mechanical Engineering, University of Aveiro, Portugal
Department of Materials Engineering, Ghent Technology Campus, KU Leuven, Belgium
Uncertainty quantification of inversely identified plastic material behavior ...vformxsteels
IDDRG 2022
M Conde1,*, S Coppieters2, A Andrade-Campos1
* marianaconde@ua.pt
1 TEMA, Department of Mechanical Engineering, University of Aveiro, Portugal
2 Department of Materials Engineering, Ghent Technology Campus, KU Leuven, Belgium
The traditional Z-Map was re-invented to a common data model for representation of geometry, attributes, physical states and other characteristics of novel manufacturing processes, which may include a multi-step operation of milling, turning, moulding and EDM (Electro-Discharge Machining), etc. The method is used to integrate these discrete point unit processes into a multi-step model for pervasive processes design and verification. A second patent has been filed to apply this method in mould design and verification.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
On the comparison of heterogeneous mechanical tests for sheet metal character...vformxsteels
IDDRG 2022
M. Gonçalves, M.G. Oliveira, S. Thuillier, A. Andrade-Campos
Centre for Mechanical Technology and Automation (TEMA),
Department of Mechanical Engineering
University of Aveiro, Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL
F-56100 Lorient, France
1
On the topology design of a mechanical heterogeneous specimen using geometric...vformxsteels
IDDRG 2022
M. Gonçalves, S. Thuillier, A. Andrade-Campos
Centre for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering,
University of Aveiro, Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
41st International Deep Drawing Research Group Conference, 6 - 10 June 2022, Lorient, France
On the topology design of an innovative heterogeneous mechanical test for mat...vformxsteels
RS 2022
On the topology design of an innovative
heterogeneous mechanical test for material
mechanical characterization
Centre for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering, University of Aveiro,
Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
Doctoral Program in Mechanical Engineering
On the topology design of an innovative heterogeneous mechanical test for mat...vformxsteels
RS2022
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
Centre for Mechanical Technology and Automation (TEMA), Department of Mechanical Engineering, University of Aveiro,
Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
1
A practical approach to eliminate defects in gravity die cast al alloy castin...eSAT Journals
Abstract
This paper deals with elimination of defects in aluminium alloy castings produced by gravity die casting process. The main intention of work is to investigate the defects and improve quality of a gravity die cast component using Computer Aided Casting Simulation Software. In this study an industrial gravity casting die is used which was producing defective components. The die and components produced by the die are studied to eliminate the defects using virtual simulations. The defects in the components are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons for the defects are analyzed as either improper selection of process parameters, or improper design of gating and risering system. SOLIDCast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. The work is carried out in two stages. In first stage, few test castings are produced by modifying the process parameters (pouring temperature, pouring time, pre heat and alloy type) and results are compared with simulation results produced using same parameters. The pouring and simulation results are observed to be in good accordance with each other. In second stage, number of virtual iterations of casting is performed by changing riser dimensions. It was found from the simulation results that riser with 35mm diameter is required to produce casting with zero defects. The die is modified accordingly with the simulation results and metal is poured. The castings produced are observed to be sound and contain no defects; and also it is verified that solidification simulation helps in locating the defects, eliminating them and ultimately improving the quality of castings without any shop-floor trails.
Keywords: Aluminum-Alloys, Casting Defects, Gravity Die Casting, Material Density and SOLIDCast Simulation
On the power of virtual experimentation in MT2.0: a VFORM-xSteels outlookvformxsteels
Sam Coppieters, A. Gil Andrade-Campos et al.
MatchID Global User Meeting
On the power of virtual experimentation in MT2.0 : a VFORM outlook
22 February2023 | Southampton, UK
Uncertainty quantification of inversely identified plastic material behavior ...vformxsteels
M Conde, S Coppieters, A Andrade-Campos
TEMA, Department of Mechanical Engineering, University of Aveiro, Portugal
Department of Materials Engineering, Ghent Technology Campus, KU Leuven, Belgium
Uncertainty quantification of inversely identified plastic material behavior ...vformxsteels
IDDRG 2022
M Conde1,*, S Coppieters2, A Andrade-Campos1
* marianaconde@ua.pt
1 TEMA, Department of Mechanical Engineering, University of Aveiro, Portugal
2 Department of Materials Engineering, Ghent Technology Campus, KU Leuven, Belgium
A nonlinear topology-based optimization approach for the design of a heteroge...vformxsteels
TechMA 2022
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
A nonlinear topology-based optimization approach for the design of a heteroge...vformxsteels
TechMA 2022
Mafalda Gonçalves, Sandrine Thuillier, António Andrade-Campos
Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Portugal
Univ. Bretagne Sud, UMR CNRS 6027, IRDL, F-56100 Lorient, France
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Design of novel heterogeneous thermomechanical tests using topology based optimization methodologies
1. Design of novel heterogeneous
thermomechanical tests using topology-based
optimization methodologies
Mafalda Gonçalves, A. Gil Andrade-Campos, Sandrine Thuillier
mafalda.goncalves@ua.pt
Year of 1st registration: 2020 (Number of full-time equivalent years: 1 year)
PhD program: Doctoral Program in Mechanical Engineering
2. ▪ Virtual manufacturing
▪ Need for reliable input data for numerical simulation
software
▪ Modelling of material behavior
▪ Standard tests - expensive and time-consuming
Research challenges
3. [1] T. Pottier, P. Vacher, F. Toussaint, H. Louche, and T. Coudert, Exp. Mech., vol. 52, no. 7, pp. 951–963, 2012.
[2] E. M. C. Jones et al., Comput. Mater. Sci., vol. 152, pp. 268–290, 2018.
[3] J. M. P. Martins, A. Andrade-Campos, and S. Thuillier, Int. J. Solids Struct., vol. 172–173, pp. 21–37, 201
[4] N. Souto, A. Andrade-Campos, and S. Thuillier, Int. J. Mater. Form., vol. 10, no. 3, pp. 353–367, 2017.
[5] L. Chamoin, C. Jailin, M. Diaz, and L. Quesada, Int. J. Solids Struct., vol. 193–194, pp. 270–286, 2020.
[6] B. Barroqueiro, A. Andrade-Campos, J. Dias-de-Oliveira, and R. A. F. Valente, Int. J. Mech. Sci., vol. 181, p. 105764, 2020.
[2] [3]
[1]
[4] [5] [6]
▪ Non-standard specimen designs
▪ Heterogeneous displacement and strain fields
▪ Higher quality and quantity of information about the
material behavior
▪ Reduced number of tests required
Heterogeneous mechanical tests
4. Research objectives and methodologies
❑ Design a suitable heterogeneous mechanical test able to
provide the largest number of strain states:
▪ Topology-based optimization methodologies
▪ Digital Image Correlation (DIC) to measure the
induced heterogeneous fields
❑ Non-linear behavior of sheets steels (plastic hardening
and anisotropy) in isothermal and heterogeneous
temperature conditions.
5. ▪ Bi-level optimization problem:
▪ Test design by Topology Optimization (TO)
▪ Optimized loading conditions and geometrical parameters
▪ Elasticity framework
▪ Innovative specimen designs with highly heterogeneous
strain fields
Current state of the work
COMPLAS 2021 – XVI International Conference on Computational Plasticity. Fundamentals and Applications.
6. Experimental validation using
full-field DIC measurements.
Parameter identification.
Next steps
Extension of structural TO to
non-linear thermoelastoplasticity
and its application to specimen
design using mechanical indicators.
Application of synthetic
images as experiments
simulator in the design of the
test.
Test design led by the
sensitivity of the displacement
field to the model parameters.
VFM identification procedure.
