ARTICLE | doi:10.20944/preprints202107.0655.v1
Subject: Materials Science, Biomaterials Keywords: cast iron with lamellar graphite; graphite microstructure; mechanical properties; thermal properties; material properties; microstructure simulations; homogenization; material data workflow
Online: 29 July 2021 (12:33:20 CEST)
The sensitivity of macroscopic mechanical and thermal properties of grey cast iron is computationally investigated for a variety of graphite microstructures over a wide temperature range. In order to represent common graphite microstructures according to DIN EN ISO 945-1, a synthetic approach is used to algorithmically generate simulation domains. The developed mechanical and thermal model is applied in a large simulation study. The study includes statistical volume elements of the graphite microstructures classes GG-15 and IA2 to IA5, with 10 v.-%, 11 v.-% and 12 v.-% graphite, respectively, for a temperature range from 20 °C to 750 °C. Homogenized macroscopic quantities such as the Young's moduli, Poisson's ratios, yield strengths and thermal conductivities are predicted for the different microstructure classes by applying simulation and data analysis tools of the research data infrastructure Kadi4Mat.
ARTICLE | doi:10.20944/preprints202107.0629.v1
Subject: Engineering, Automotive Engineering Keywords: phase-field; multiphase-field; grey cast iron; brittle fracture; ductile fracture; anisotropic fracture
Online: 28 July 2021 (12:16:13 CEST)
In this work, a small-strain phase-field model is presented, which is able to predict crack propagation in systems with anisotropic brittle and ductile constituents. To model the anisotropic brittle crack propagation, an anisotropic critical energy release rate is used. The brittle constituents behave linear-elastically, in a transversely isotropic manner. Ductile crack growth is realised by a special crack degradation function, depending on the accumulated plastic strain, which is calculated by following the J2-plasticity theory. The mechanical jump conditions are applied in solid-solid phase transition regions. The influence of the relevant model parameters on a crack, propagating through a planar brittle-ductile interface, and furthermore a crack developing in a domain with a single anisotropic brittle ellipsoid, embedded in a ductile matrix, is investigated. We demonstrate that important properties, concerning the mechanical behaviour of grey cast iron, such as the favoured growth of cracks along the graphite lamellae and the tension-compression load asymmetry of the stress-strain response, are covered by the model. The behaviour is analysed on basis of a simulation domain consisting of three differently oriented elliptical inclusions, embedded in a ductile matrix, which is subjected to tensile and compressive load. The used material parameters correspond to graphite lamellae and pearlite.
ARTICLE | doi:10.20944/preprints202012.0312.v1
Subject: Engineering, Automotive Engineering Keywords: Bayesian Network; Root Cause Analysis; Failure Mode and Effect Analysis; Lithium-Ion 15 Battery Cell; Failure Propagation; Multi-Stage Production; Manufacturing Process; Process Optimization; Scrap Rate
Online: 14 December 2020 (09:31:30 CET)
The production of lithium-ion battery cells is characterized by a high degree of complexit due to numerous cause-effect relationships between process characteristics. Knowledge about the multi-stage production is spread among several experts, rendering tasks such as failure analysis challenging. In this paper, a method is presented, which includes expert knowledge acquisition in production ramp-up by combining Failure Mode and Effects Analysis (FMEA) with a Bayesian Network. We show the effectiveness of this holistic method by building up a large scale, cross-process Bayesian Failure Network in lithium-ion battery production. Using this model, we are able to conduct root cause analyses as well as analyses of failure propagation. The former support operators in identifying root causes once a cell possesses a specific failure by calculating most-probable explanations matched to the individual battery cell data. The latter enable us to analyze propagation of failures and deviations in the production chain and thus provide support for placement of quality gates, leading to a significant reduction in scrap rate. Moreover, it gives an insight into which process steps are key drivers for which final product characteristics.