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Numerical simulation of steady states associated with thermomechanical processes

Abstract : In the numerous thermomechanical manufacturing processes such as rolling, welding, or even machining involve either moving loads with respect to the fixed material or moving material with respect to fixed loads. In all cases, after a transient regime which is generally quite short, the thermal, metallurgical, and mechanical fields associated with these processes reach a steady state. The search for these stationary states using the classical finite element method requires the implementation of complex and expensive models where the loads move with respect to the material (or vice versa). The steady-state simulation in one increment has been the subject of much researches over the past thirty years. Methods are now available and some are integrated into calculation codes commercial. Thus, a so-called Moving Reference Frame method proposed by various authors is available in the SYSWELD software. This method makes it possible to calculate the steady-state of thermal, metallurgical, and mechanical states associated with a welding process, by solving a thermal diffusion-convection problem in thermal-metallurgy and by integrating, in mechanics, the constitutive equations of the material along the streamline. Moreover, this method has been used successfully in many applications, it nevertheless has some limitations. Thus the mesh must be structured and the convergence of computations is generally quite slow. In this thesis, we propose to solve the mechanical problem in a frame linked to the solicitations, by relying on a finite element calculation method based on nodal integration and the SCNI (Stabilized Conforming Numerical Integration) technique. This method allows the use of tetrahedron meshes (or 2D triangles) without encountering a locking problem resulting from the plastic incompressibility associated with the von Mises plasticity criterion. Rather than directly calculating the steady-state, the general idea here is to construct the steady-state from a transient analysis by bringing material step by step upstream and by making it exit downstream of a fixed mesh related to the solicitations and of the limited mesh size. The steady-state is therefore only achieved after certain steps of analysis. Apart from a general introduction (Chapter 1) and a state of the art on the existing methods (Chapter 2), we present an approach of simulation of the movement of material within the framework of the classical finite element method on a welding problem (Chapter 3). We also provide relevant thermal boundary conditions for directly calculating the steady-state of temperature distribution. The finite element method based on the nodal integration technique is then described in Chapter 4. The advantages and disadvantages of the method are discussed. The nodal-integration-based finite element is validated by comparing its simulation results with classical finite element methods in large elastoplastic strains, a bending problem, and a thermomechanical simulation of welding. The nodal-integration-based finite element is then developed and applied to simulate material motion (Chapter 5). Three types of movement are considered: translational, circular, and helical. Different methods of field transport are approached and discussed as well as thermomechanical coupling. Perspectives for this work are presented in Chapter 6. The envisaged perspectives aim, on the one hand, to improve the proposed method and on the other hand, to develop the method to simulate other processes. A first application of the material motion method to the simulation of the orthogonal cut is presented there.
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Submitted on : Friday, July 22, 2022 - 5:37:12 PM
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Yabo Jia. Numerical simulation of steady states associated with thermomechanical processes. Other. Université de Lyon, 2020. English. ⟨NNT : 2020LYSEE007⟩. ⟨tel-03736799⟩

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