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EVALUATION AND OPTIMIZATION OF TENSILE STRENGTH

RESPONSES OF COPPER AT SUB ZERO TEMPERATURES


USING TAGUCHI ROBUST DESIGN AND MACHINE LEARNING

PRESENTED BY
GUIDED BY DINESH VARMA
(12241A0373)
DR. SWADESH KUMAR SINGH DEVARAJU ADHARAVENI
(12241A0361)
RAVINDER MUPPIDI
(13245A0314)
MADHU
(13245A0319)
CONTENTS TO BE COVERED

 Abstract
 Introduction
 Experiment
 Taguchi Method
 Machine Learning
 Experimental Data
 Results and Discussion
 Conclusion
INTRODUCTION

Objectives

 To find the flow stress using Computer controlled UTM

 To predict the flow stress of alloy using Johnson Cook Model

 Resources to be used:

 CNC Milling Machine

 Vernier callipers

 Computer Controlled UTM

 Mat lab 2013


MATERIAL

 Zirconium is a commercially available refractory metal with excellent properties like


Composition
1. Corrosion resistance
2. Good mechanical properties
3. Very low thermal neutron cross section
4. Can manufactured by standard fabrication methods
Zirconium Tin
Symbol Zr Chromium Iron

Discoverer Martin Heinrich


Discoverer In 1789
MATERIAL IN PERIODIC TABLE
SPECIMEN AND ITS PREPARATION

Dimensions of the UTM specimen for tensile


testing (in mm)
EXPERIMENT
 The Zircalloy-4, with less oxygen content, of 1mm thick sheet was
milled into tensile test samples in rolling direction.
 The tensile tests were conducted on a computer controlled UTM,
shown in Fig., which has a maximum load capacity of 100kN. The
machine is equipped with a control system to impose an
exponential increase of the actuator speed to obtain
displacement . A contact type extensometer is used to measure
the strains. The resistance heating split furnace is used to heat the
tensile test specimen up to 423K.
Strain Rates Used Temperature Used
0.001 s-1 298 K Fig : Tensile test data range for JC model development
0.005 s-1 348 K
0.01 s-1 423 K
JOHNSON COOK MODEL

 Development of Stresses in Johnson Cook Model depends on three independent phenomena

- Strain Rate Hardening


- Isotropic Hardening
- Thermal Hardening
  
where is the Von-mises flow stress A indicates the yield stress at reference
temperature and reference strain rate, B indicates the coefficient of strain hardening,
indicates the true plastic strain, is strain hardening exponent, is the coefficient of strain
rate hardening, , where is true strain rate, is the reference strain rate, is the homologous
temperature and the is the thermal softening exponent.
ISOTROPIC HARDENING

 For isotropic hardening, if you


plastically deform a solid, then
unload it, then try to reload it
again, you will find that its yield
stress (or elastic limit) would
have increased compared to
what it was in the first cycle.
This is isotropic hardening.
STRAIN RATE HARDENING
 The strain rate hardening is used to express the increase of flow stress with the increase of loading

strain rate.

 Strain hardening is related to the increase in flow stress by increasing strain as a result of

(1) Interaction of the stress fields of the dislocations.

(2) Back-stress resulting from dislocation pile-ups at barriers which are sessile dislocations such as Lomer-
Cottrell barriers.

(3) Dislocation intersections which results in a small step or jog in the dislocation line and restricts its
motion.

 Strain rate hardening is related to increase in flow stress by increasing strain rate as a result of high

value of the strain rate sensitivity (m), which is one of the major requirements to inhibit necking
during deformation.
THERMAL HARDENING
 In thermal hardening a hard layer is formed at the surface of plain carbon and low alloy

steels of medium carbon content (0.3 - 0.6%) by heating the steel till it reaches the
austenistising temperature (about 850oC, depending upon carbon content) then rapidly
quenching it to form a martensitic structure.

 The depth of hardening can be controlled by the rate of heating, rapid heating for a 5 - 20

seconds with an induction coil will limit the hardened zone to material adjacent to the
surface. The more rapid the cooling the greater will be the depth of hardening (up to the
limit of the austenitised zone) - the thinner the section the easier it is to cool rapidly.
However the faster the quench the greater the danger of distortion or cracking. Increasing
alloying content also gives greater depth of hardening and will allow a less severe quench
to be used.

 The depth of hardening is normally in the range of 1 - 5 mm.


DETERMINATION OF MATERIAL CONSTANTS IN JC
MODEL

 Step 1: At reference strain rate and reference temperature.


 Step 2: At a fixed strain and reference temperature.
 Step 3: At a fixed strain and reference strain rate.
 Step 4: Optimization of the C and m values.
 Step 5: Predictability of the constitutive equation.

All the above equations are solved by using MATLAB.


Material constants for JC model

Material A B C n m
Constant
Value 283 774.2 0.0152 0.8499 0.8012
EXPERIMENTAL DATA
Displaceme Load
nt (mm) (KN) Displacement vs Load Data
0 0
0 0.01
0.01 0.01
Direction – Longitudinal Temperature - 298k
0.01 0.02 Strain Rate - 0.001
0.02 0.02
0.03 0.02 Load vs Displacement
0.03 0.03
0.03 0.02
0.03 0.03
2.5
0.04 0.03
0.05 0.03 2
0.05 0.04
0.06 0.04 1.5

Load(KN)
0.07 0.04
1
0.07 0.05
0.07 0.04 0.5
0.07 0.05
0.07 0.04 0
0 2 4 6 8 10 12 14
0.07 0.05 Displacement (mm)
0.08 0.05
RESULTS AND DISCUSSION

  

The equation for JC model is given by


RESULTS AND DISCUSSION

Figures show the predicted values of flow stress


for JC model at strain rates of 0.01, 0.005 and
0.001s-1. However, the R value for the model
came out to be 0.7616(as shown in Fig. ) and
value of average absolute error was 11.95% and
standard deviation of 12.13. The predictive
capability of the JC model is low mainly due to
the influence of the coupled effect of strain and
temperature, and of strain rate and
temperature. Correlation between experimental and predicted stress
CONCLUSION

 We have experimentally found the flow stress of the alloy at


different temperature and different strain rates
 We have developed the Johnson cook model for the alloy at
different temperature and different strain rates
 We have optimized the parameter of Johnson Cook model for the
alloy
 We have predicted the flow stress using Johnson Cook model

Hence, it can be concluded that the flow behaviour of Zircalloy-4 with low oxygen content
at elevated temperature is not governed by three independent phenomena, viz., thermal
softening, strain rate hardening and isotropic strain hardening but a combination of them.
THANK YOU

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