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Optimal control of multiphase steel production
An optimal control problem for the production of multiphase steel is investigated that takes into account phase transformations in the steel slab. The state equations are a semilinear heat equation coupled with an ordinary differential equation, that describes the evolution of the steel microstructure. The time-dependent heat transfer coefficient serves as a control function. Necessary and sufficient optimality conditions for the control problem are derived. For the numerical solution of the control problem, a reduced sequential quadratic programming method with a primal-dual active set strategy is developed. The numerical results are presented for the optimal control of a cooling line in the production of hot-rolled Mo–Mn dual phase steel. © 2019, The Author(s).
Topology optimization subject to additive manufacturing constraints
In Topology Optimization the goal is to find the ideal material distribution in a domain subject to external forces. The structure is optimal if it has the highest possible stiffness. A volume constraint ensures filigree structures, which are regulated via a Ginzburg-Landau term. During 3D Printing overhangs lead to instabilities, which have only been tackled unsatisfactorily. The novel idea is to incorporate an Additive Manufacturing Constraint into the phase field method. A rigorous analysis proves the existence of a solution and leads to first order necessary optimality conditions. With an Allen-Cahn interface propagation the optimization problem is solved iteratively. At a low computational cost the Additive Manufacturing Constraint brings about support structures, which can be fine tuned according to engineering demands. Stability during 3D Printing is assured, which solves a common Additive Manufacturing problem.
Numerical simulation of high-frequency induction welding in longitudinal welded tubes
In the present paper the high-frequency induction (HFI) welding process is studied numerically. The mathematical model comprises a harmonic vector potential formulation of the Maxwell equations and a quasi-static, convection dominated heat equation coupled through the joule heat term and nonlinear constitutive relations. Its main novelties are twofold: A new analytic approach permits to compute a spatially varying feed velocity depending on the angle of the Vee-opening and additional spring-back effects. Moreover, a numerical stabilization approach for the finite element discretization allows to consider realistic weld-line speeds and thus a fairly comprehensive three-dimensional simulation of the tube welding process.
Modelling and simulation of flame cutting for steel plates with solid phases and melting
The goal of this work is to describe in detail a quasi-stationary state model which can be used to deeply understand the distribution of the heat in a steel plate and the changes in the solid phases of the steel and into liquid phase during the flame cutting process. We use a 3D-model similar to previous works from Thiebaud [1] and expand it to consider phases changes, in particular, austenite formation and melting of material. Experimental data is used to validate the model and study its capabilities. Parameters defining the shape of the volumetric heat source and the power density are calibrated to achieve good agreement with temperature measurements. Similarities and differences with other models from literature are discussed.
Weak entropy solutions to a model in induction hardening, existence and weak-strong uniqueness
In this paper, we investigate a model describing induction hardening of steel. The related system consists of an energy balance, an ODE for the different phases of steel, and Maxwell's equations in a potential formulation. The existence of weak entropy solutions is shown by a suitable regularization and discretization technique. Moreover, we prove the weak-strong uniqueness of these solutions, i.e., that a weak entropy solutions coincides with a classical solution emanating form the same initial data as long as the classical one exists. The weak entropy solution concept has advantages in comparison to the previously introduced weak solutions, e.g., it allows to include free energy functions with low regularity properties corresponding to phase transitions.
Structural multiscale topology optimization with stress constraint for additive manufacturing
In this paper a phase-field approach for structural topology optimization for a 3D-printing process which includes stress constraint and potentially multiple materials or multiscales is analyzed. First order necessary optimality conditions are rigorously derived and a numerical algorithm which implements the method is presented. A sensitivity study with respect to some parameters is conducted for a two-dimensional cantilever beam problem. Finally, a possible workflow to obtain a 3D-printed object from the numerical solutions is described and the final structure is printed using a fused deposition modeling (FDM) 3D printer.
Comparison of monomorphic and polymorphic approaches for uncertainty quantification with experimental investigations
Unavoidable uncertainties due to natural variability, inaccuracies, imperfections or lack of knowledge are always present in real world problems. To take them into account within a numerical simulation, the probability, possibility or fuzzy set theory as well as a combination of these are potentially usable for the description and quantification of uncertainties. In this work, different monomorphic and polymorphic uncertainty models are applied on linear elastic structures with non-periodic perforations in order to analyze the individual usefulness and expressiveness. The first principal stress is used as an indicator for structural failure which is evaluated and classified. In addition to classical sampling methods, a surrogate model based on artificial neural networks is presented. With regard to accuracy, efficiency and resulting numerical predictions, all methods are compared and assessed with respect to the added value. Real experiments of perforated plates under uniaxial tension are validated with the help of the different uncertainty models.