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Fluctuations of material properties are one reason for the occurrence of cracks and waviness in series production of car body parts. Especially fluctuating tribological conditions have an effect on the friction behavior and thus on the material flow. So far fluctuating material properties are not considered in the standard FE-simulation and consequently not in the tool design. In order to enhance the accuracy of the simulation result and thus improve the tool design regarding a robust process, the appearance of batch fluctuations has to be consistently understood. Therefore, the impact of varying lubricant quantities and roughness have been investigated. Several batches have been analyzed to identify the main influencing parameter regarding the friction behavior. Flat strip-drawing tests have been performed to determine the friction coefficient. The investigations have been performed by using material from the series production, as delivered. Since the amount of lubricant turns out to be the main influencing factor, the characteristics and appearance of the lubricant distribution has been analyzed in a further step. The analysis has shown that the distribution of the lubricant changes within one coil over the coil width and length. In addition, the time of storage has been identified as one main influencing factor on the homogeneity of the lubricant distribution over the coil width. Based on these findings, a method has been developed to map the series production conditions regarding the friction conditions in the simulation. Hence, simulations were performed using a side frame blank with different friction conditions, to investigate the impact on the forming result. The results reveal that by considering realistically existing tribological conditions, more scrap is to be expected compared to the conventional simulation. This leads to the conclusion that previous simulation results are too optimistic. Consequently, the introduced method offers the potential to optimize the tool design by considering fluctuating tribological conditions already in the process of development. Thus, it is possible to reduce scrap and increase productivity.
The current analyses present results of running ductile fracture propagation in high strength X100 line pipe steels under the influence of anisotropy. Mechanical anisotropy is commonly available in pipe products as a result of the manufacturing process, especially, those subjected to hot/cold-worked deformation. The outcomes of the present analyses show that its effect on the behavior of running ductile fracture in cracked pipes undergoing depressurization is meaningful. For instance, the Crack-Tip Opening Angle (CTOA) not only exhibits a strong dependence to the pipe's diameter size, but also to the material's anisotropy nature when compared to a hypothetical isotropic material. Moreover, laboratory scale tests such as those performed on Battelle Drop Weight Tear (BDWT) samples provide useful information about initiation of ductile crack propagation when the anisotropy features are taken into account in the material description.
Abrasive wear limits the lifetime of many machine components. Most empirical models relate the abrasive wear resistance to material hardness. In reality, however, other material properties are also influencing as scratch abrasion damage follows from a highly complex stress trajectory upon scratching. Numerical (finite element) simulation of scratch abrasion requires the use of a material damage model, which translates this stress trajectory into material degradation and removal. Most damage models include the first two stress invariants. However, fully incorporating the complex stress trajectories that occur during scratch abrasion may require damage models with dependence of the third deviatoric parameter (Lode angle). This paper serves as an a-priori study to evaluate the stress states that may occur during scratch abrasion. Three mechanisms (ploughing, wedging, cutting) are considered. Hereto, the results of an extensive parametric study using elastic-plastic finite element simulations of a scratch indentation process are discussed. Complex, non-proportional variations in stress state values are observed to occur during scratch abrasion. Distinct stress state trajectories are identified for the three abovementioned mechanisms. These variations are critically discussed to motivate a selection of suitable damage models for rigorous finite element analysis of the wear processes associated with scratch abrasion.
The magnetic properties of a magnetoactive elastomer (MAE) filled with mu m-sized soft-magnetic iron particles have been experimentally studied in the temperature range between 150 K and 310 K. By changing the temperature, the elastic modulus of the elastomer matrix was modified, and it was possible to obtain magnetization curves for an invariable arrangement of particles in the sample and in the case when the particles were able to change their position within the MAE under the influence of magnetic forces. At low (less than 220 K) temperatures, when the matrix becomes rigid, the magnetization of the MAE does not show a hysteresis behavior, and it is characterized by a negative value of the Rayleigh constant. At room temperature, when the polymer matrix is compliant, a magnetic hysteresis exists where the dependence of the differential magnetic susceptibility on the magnetic field exhibits local maxima. The appearance of these maxima is explained by the elastic resistance of the matrix to the displacement of particles under the action of magnetic forces.
To investigate the combustion and emission behavior of straight vegetable oils (SVO), jatropha oil, soybean oil, and diesel fuel were tested. For this research, a 2.2L common-rail engine with a two-stage turbocharging concept was equipped with a cylinder pressure indication system, an exhaust-gas analyzer, an AVL Micro Soot sensor and a Scanning Mobility Particle Sizer 3936 (SMPS) device to detect the particle-size-distribution (PSD). At a low and mid-load engine-operating point (EOP), the thermodynamic and emissions were investigated under various exhaust gas recirculation (EGR) rates with respect to the PSD. Moreover, the injection behavior of the three test fuels was analyzed separately using an injection rate analyzer. This procedure facilitates the thermodynamic investigations of the engine process and allows the calculation of the hydraulic delay (HD) as well as the ignition delay (ID). The ID of the SVO fuels compared to diesel fuel was found to be lower at all engine-operating modes, while jatropha oil always showed the shortest ID. In the particulate-nitrogen oxide (NOX) trade-off, the SVO fuels showed higher particulate matter (PM) emissions at the low-load EOP, whereas the PM emissions of diesel fuel overtop the SVO fuels at a higher engine load. With increased EGR-rates, a rise in the particle size was observed for all fuels. At the low-load EOP, the SVO fuels showed larger particles for high EGR-rates. This effect also changed by increasing the engine-load to the mid-load EOP, wherein the particle size of the diesel fuel emissions is higher by applying elevated EGR-rates.
Magnetodielectric properties of magnetoactive elastomers comprising micrometer-sized iron particles dispersed in compliant elastomer matrices are experimentally studied in stepwise time-varying dc magnetic fields. It is found that imposition of magnetic field significantly increases both the effective lossless permittivity of these composite materials as well as their effective conductivity. These magnetodielectric effects are more pronounced for larger concentrations of soft-magnetic filler particles and softer elastomer matrices. The largest observed relative change of the effective dielectric constant in the maximum magnetic field of 0.57 T is of the order of 1000%. The largest observed absolute change of the loss tangent is approximately 0.8. The transient response of the magnetodielectric effect to a step magnetic-field excitation can be rather complex. It changes from a simple monotonic growth with time for small magnetic-field steps (<0.1 T) to a non-monotonic behavior with a significant rapidly appearing overshoot for large magnetic-field steps (>0.3 T). The settling time to the magnetic-field step excitation can reach roughly 1000 s and it depends on the applied magnetic field and sample composition. There is also significant hysteresis of the magnetodielectric effect on the externally applied magnetic field. These findings are attributed to the rearrangement of ferromagnetic filler particles in external magnetic fields. The results will be useful for understanding and predicting the transient behavior of magnetoactive elastomers in applications where the control magnetic field is time dependent. (C) 2017 Elsevier Ltd. All rights reserved.
The dynamic shear modulus of magnetoactive elastomers containing 70 and 80 mass % of carbonyl iron microparticles is measured as a function of strain amplitude via dynamic torsion oscillations in various magnetic fields. The results are presented in terms of the mechanical energy density and considered in the framework of the conventional Kraus model. The form exponent of the Kraus model is further related to a physical model of Huber et al. [Huber et al., J. Phys.: Condens. Matter 8, 409 (1996)] that uses a realistic representation for the cluster network possessing fractal structure. Two mechanical loading regimes are identified. At small strain amplitudes the exponent beta of the Kraus model changes in an externally applied magnetic field due to rearrangement of ferromagnetic-filler particles, while at large strain amplitudes, the exponent beta seems to be independent of the magnetic field. The critical mechanical energy characterizing the transition between these two regimes grows with the increasing magnetic field. Similarities between agglomeration and deagglomeration of magnetic filler under simultaneously applied magnetic field and mechanical shear and the concept of jamming transition are discussed. It is proposed that the magnetic field should be considered as an additional parameter to the jamming phase diagram of rubbers filled with magnetic particles.
The influence of an external magnetic field on the static shear strain and the effective shear modulus of a magnetoactive elastomer (MAE) is studied theoretically in the framework of a recently introduced approach to the single-particle magnetostriction mechanism [V. M. Kalita et al., Phys. Rev. E 93, 062503 (2016)]. The planar problem of magnetostriction in an MAE with magnetically soft inclusions in the form of a thin disk (platelet) having the magnetic anisotropy in the plane of this disk is solved analytically. An external magnetic field acts with torques on magnetic filler particles, creates mechanical stresses in the vicinity of inclusions, induces shear strain, and increases the effective shear modulus of these composite materials. It is shown that the largest effect of the magnetic field on the effective shear modulus should be expected in MAEs with soft elastomer matrices, where the shear modulus of the matrix is less than the magnetic anisotropy constant of inclusions. It is derived that the effective shear modulus is nonlinearly dependent on the external magnetic field and approaches the saturation value in magnetic fields exceeding the field of particle anisotropy. It is shown that model calculations of the effective shear modulus correspond to a phenomenological definition of effective elastic moduli and magnetoelastic coupling constants. The obtained theoretical results compare well with known experimental data. Determination of effective elastic coefficients in MAEs and their dependence on magnetic field is discussed. The concentration dependence of the effective shear modulus at higher filler concentrations has been estimated using the method of Pade approximants, which predicts that both the absolute and relative changes of the magnetic-field-dependent effective shear modulus will significantly increase with the growing concentration of filler particles.
Transient magnetorheological response of magnetoactive elastomers to step and pyramid excitations
(2016)
Transient rheological response of magnetoactive elastomers is experimentally studied using dynamic torsion at a fixed oscillation frequency in temporally stepwise changing magnetic fields and oscillation amplitudes. For step magnetic-field excitations, at least three exponential functions are required to reasonably describe the time behavior of the storage shear modulus over long time scales (>10(3) s). The deduced characteristic time constants of the corresponding rearrangement processes of the filler network differ approximately by one order of magnitude: tau(1) less than or similar to 10(1) s, tau(2) similar to 10(2) s, and tau(3) similar to 10(3) s. The sudden imposition of the external magnetic field activates a very fast rearrangement process with the characteristic time under 10 s, which cannot be determined more precisely due to the measurement conditions. Even more peculiar transient behavior has been observed during pyramid excitations, when either the external magnetic field was first stepwise increased and then decreased in a staircase manner at a fixed strain amplitude gamma or the strain amplitude gamma was first stepwise increased and then decreased in a staircase manner at a fixed magnetic field. In particular, the so-called "cross-over effect'' has been identified in both dynamical loading programs. This cross-over effect seems to be promoted by the application of the external magnetic field. The experimental results are discussed in the context of the specific rearrangement of the magnetic filler network under the simultaneous action of the external magnetic field and shear deformation. Striking similarities of the observed phenomena to the structural relaxation processes in glassy materials and to the jamming transition of granular materials are pointed out. The obtained results are important for fundamental understanding of material behavior in magnetic fields as well as for the development of devices on the basis of magnetoactive elastomeric materials.
Magnetoactive elastomers (MAEs) are composite materials comprised of micrometer-sized ferromagnetic particles in a nonmagnetic elastomermatrix. Asingle-particle mechanism ofmagnetostriction in MAEs, assuming the rotation of a soft magnetic, mechanically rigid particle with uniaxial magnetic anisotropy in magnetic fields is identified and considered theoretically within the framework of an alternative model. In this mechanism, the total magnetic anisotropy energy of the filling particles in the matrix is the sum over single particles. Matrix displacements in the vicinity of the particle and the resulting direction of the magnetization vector are calculated. The effect of matrix deformation is pronounced well if the magnetic anisotropy coefficient K is much larger than the shear modulus mu of the elastic matrix. The feasibility of the proposed magnetostriction mechanism in soft magnetoactive elastomers and gels is elucidated. The magnetic-field-induced internal stresses in the matrix lead to effects of magnetodeformation and may increase the elastic moduli of these composite materials.