Multi-scale numerical simulation and verification of hot forming process of high-temperature alloy disk

High-temperature alloy is a metal material with excellent performance in high-temperature environment,which is widely used in aerospace,energy,chemical industry and other fields.The hot forming process of high-temperature alloy disk is an important link in the manufacture of high-temperature alloy parts.The control and optimization of the process are crucial to improving product quality and production efficiency.This paper will discuss the multi-scale numerical simulation and verification of the hot forming process of high-temperature alloy disk,in order to provide scientific basis and technical support for the hot forming process of high-temperature alloy disk.

Ⅰ.Overview of hot forming process of high temperature alloy disc

The hot forming process of high temperature alloy disks is to heat the high temperature alloy sheet to a certain temperature,and then plastic ally deform it through a die or rolling mill to make its shape and size meet the design requirements.During this process,the micro-structure of the high temperature alloy will evolve,and the macroscopic deformation will also be affected by many factors.

Therefore,studying the multi-scale numerical simulation of the hot forming process of high temperature alloy disks is of great significance for revealing the macroscopic and microscopic behaviors in the process.

Ⅱ.Multi-scale numerical simulation method

The multi-scale numerical simulation method is a research method that combines the macro and micro scales.By constructing a macro-micro multi-scale finite element model,the macroscopic deformation and micro-structural evolution behavior of high-temperature alloy disks during hot forming can be systematically studied.

1.Finite element method and molecular dynamics method

The multi-scale simulation method is mainly composed of the coupling of the finite element method(FEM)and the molecular dynamics method(MD).The finite element method is mainly applicable to simulation calculations in continuous areas,while the molecular dynamics method is applicable to simulation calculations in atomic(molecular)areas.The unit scale in the finite element method can be refined and encrypted to the atomic scale,and the cross-scale connection is achieved by corresponding the position of the node with the atomic position in molecular dynamics.

2.CLS Method

The CLS method is one of the methods that is easy to implement in multi-scale simulation analysis.When using this method for multi-scale research,the total Hamiltonian of the system can be defined.By differentiating the Hamiltonian,the motion equations of the relevant variables can be obtained.The update of the variable values is completed by the time algorithm.The entire multi-scale model includes the finite element zone,the molecular dynamics zone and the transition zone.

Ⅲ.Multi-scale numerical simulation of hot forming process of high temperature alloy disk

In order to systematically and comprehensively study the hot forming process of high-temperature alloy disk,a macro-micro multi-scale finite element model of GH2132 high-temperature alloy disk was constructed by establishing a macro-micro material model of the high-temperature alloy and setting the hot forming process parameters and boundary conditions.

1.Model building

In the process of model building,the physical characteristics,boundary conditions and constraints of the actual problem should be fully considered,and measured data should be incorporated to improve the authenticity of the model.The accuracy of the model directly affects the credibility of the numerical simulation results.

2.Numerical simulation process

By numerically simulating the hot forming process of high-temperature alloy disks,the macroscopic deformation and micro-structural evolution behaviors during the hot forming process of high-temperature alloy disks were studied.The macroscopic deformation includes the plastic deformation and temperature distribution of the plate,and the micro-structural evolution includes the growth and re crystallization of grains.

3.Numerical simulation results

The numerical simulation results show that the macroscopic deformation and micro-structural evolution of the high-temperature alloy disk during the hot forming process are affected by many factors,including temperature,deformation rate,die shape,etc.The numerical simulation can accurately predict the macroscopic deformation and micro-structural evolution of the high-temperature alloy disk during the hot forming process.

Ⅳ.Physical test verification of hot forming process of high temperature alloy disk

In order to verify the accuracy and reliability of the numerical simulation results,physical tests of hot forming of high-temperature alloy disks were carried out.

1.Test materials

The test material is GH2132 high-temperature alloy plate,whose chemical composition and mechanical properties meet the relevant standards.

2.Test equipment

The test equipment includes heating furnace,rolling mill,molds,etc.to ensure that the test process can simulate actual production conditions.

3.Experimental steps

The test steps include heating,rolling(or forging),cooling,etc.The specific parameters are set according to the numerical simulation results.

4.Test results

The experimental results show that the macroscopic deformation state and micro-structure distribution of the high-temperature alloy disk after hot forming are consistent with the numerical simulation results,verifying the accuracy and reliability of the numerical simulation method.

Ⅴ.Optimization of hot forming process of high temperature alloy disc

Based on the results of multi-scale numerical simulation and physical test verification,the hot forming process of high-temperature alloy disks can be optimized.

1.Process parameter optimization

By adjusting process parameters such as heating temperature,deformation rate,and mold shape,the hot forming process of high-temperature alloy disks can be optimized to improve product quality and production efficiency.

2.Material performance optimization

By improving the chemical composition and heat treatment process of high-temperature alloys,the micro-structure of the material can be optimized and the mechanical properties and thermal stability of the material can be improved.

3.Mold design optimization

By optimizing the design of the mold,the friction and wear between the mold and the high-temperature alloy plate can be reduced,and the service life of the mold and the precision of the product can be improved.

Ⅵ.Hot forming processing method of high temperature alloy sheet

The hot forming processing methods of high-temperature alloy plates include hot rolling,forging,isotherm forging and hot extrusion.

1.Hot rolling

Hot rolling is to heat the high temperature alloy sheet to a certain temperature,and then pass it through the rolling mill to make its shape and size meet the requirements.Hot rolling has the advantages of high production efficiency and low cost,and is suitable for large-scale production.

2.Forging

Forging is a method of plastic ally deforming high-temperature alloy sheets through a die.During the forging process,the high-temperature alloy sheet is heated to a certain temperature and then placed in a die for forging to make its shape and size meet the requirements.Forging has high processing accuracy and good mechanical properties,and is suitable for manufacturing parts with high precision requirements.

3.Isothermal forging

Isothermal forging is a method of forging under constant temperature conditions.During the isotherm forging process,the high-temperature alloy sheet is heated to a certain temperature and then placed in a mold for isothermal forging to make its shape and size meet the requirements.Isothermal forging has the advantages of high processing accuracy,good mechanical properties,and uniform deformation.It is suitable for manufacturing parts with high precision requirements.

4.Hot extrusion molding

Hot extrusion is a method of extruding and deforming high-temperature alloy sheets through an ext-ruder.During the hot extrusion process,the high-temperature alloy sheet is heated to a certain temperature and then placed in an ext-ruder for extrusion to make its shape and size meet the requirements.Hot extrusion is suitable for manufacturing parts with complex shapes and high dimensional accuracy requirements.

VII.Conclusion and Outlook

This paper studies the multi-scale numerical simulation and verification of the hot forming process of high-temperature alloy disks.By constructing a macro-micro multi-scale finite element model,the macro deformation and micro-structural evolution behavior during the hot forming process of high-temperature alloy disks are systematically studied.The numerical simulation results show that the macro deformation and micro-structural evolution during the hot forming process of high-temperature alloy disks can be accurately predicted by numerical simulation.Physical tests verify the accuracy and reliability of the numerical simulation results.Based on the results of numerical simulation and physical test verification,the hot forming process of high-temperature alloy disks is optimized.

In the future,we will further study the micro-structure evolution mechanism in the hot forming process of high-temperature alloy disks,explore more efficient numerical simulation methods and optimization algorithms,and provide more accurate and reliable technical support for the hot-forming process of high-temperature alloy disks.At the same time,attention will be paid to the innovation and development of high-temperature alloy materials,and the continuous progress and application expansion of the hot forming process of high-temperature alloy discs will be promoted.

Through the discussion in this article,we have systematically understood the multi-scale numerical simulation and verification of the hot forming process of high-temperature alloy discs.In the future,with the continuous advancement of numerical simulation methods and experimental technology,the optimization and application of the hot forming process of high-temperature alloy discs will achieve more significant results.