Single-Course English 5 ECTS

Modelling in materials and manufacturing engineering – thermomechanics

Overall Course Objectives

The overall objective of the course is to give the students understanding and knowledge of numerical modelling of materials and manufacturing engineering with special focus on thermomechanical phenomena in welding, surface hardening and manufacturing of composites. The students will learn about modeling (numerical as well as analytical) methods for thermal stresses and strains during manufacturing in metals and composites. This is achieved by programming the numerical methods themselves as well as applying commercial software.
The applied methods are of general nature and can be applied in a wide range of industrial branches, for example automotive, maritime as well as wind energy.

Explain the concepts of thermal strains and thermal stresses
Understand how volumetric strains (thermal, chemical..) play together with classical elasto-plastic theory as well as classical laminate theory
Apply numerical as well as analytical methods to calculate thermal stresses in processes like welding, additive manufacturing, surface hardening and resin transfer moulding
Use Matlab to solve partial differential equations
Use Matlab to solve thermomechanical problems
Evaluate the validity of numerical methods by comparison with relevant analytical solutions
Assess the possibilities of solving thermal stress problems with analytical and numerical methods
Explain the importance of thermally induced residual stresses for the subsequent mechanical performance of manufactured parts

Lectures:
Numerical methods for simulation of thermal processing of materials including welding, additive manufacturing, surface hardening and resin transfer moulding. Basic thermomechanics. Thermal strain. Thermal stress. Internal and external constraints. Thermoelasticity. Numerical and analytical solutions. Thermal stresses in surfaces – application to surface hardening and casting. Thermomechanics in curing of composite laminates. Thermal and chemical strains in classical laminate theory. Thermo-elasto-plasticity. The return mapping algorithm. Thermomechanical analysis in welding and additive manufacturing. The Satoh test. Transient and residual stresses.

Computer exercises:
Setting up and programming algorithms as well as using commercially available FE-software for thermomechanical simulation of surface hardening, curing of composites, welding and additive manufacturing

Programming environment: Matlab

Knowledge of basic process technology 42201/42911/41704/41784. Knowledge of materials technology corresponding to 41681/41650/41659. Knowledge of modelling in materials and manufacturing engineering corresponding to 41747. Knowledge of mathematics corresponding to 01035 (possibly in parallel). Knowledge of strength of materials corresponding to 41502

N.B.: For students who do not have experience in programming in Matlab, a crash-course of one afternoon in basic Matlab will be given prior to the course.

Lectures and exercises