Vol. 25 No. 3 2023 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 25 No. 3 2023 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Aff airs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, Institute of Strength Physics and Materials Science, Russian Academy of Sciences (Siberian Branch), Tomsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 25 No. 3 2023 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Salikhyanov D.R., Michurov N.S. Simulation of the rolling process of a laminated composite AMg3/ D16/AMg3.......................................................................................................................................................... 6 Ilinykh A.S., Pikalov A.S., Miloradovich V.K., Galay M.S. Experimental studies of high-speed grinding rails modes.......................................................................................................................................................... 19 Salikhyanov D.R., Michurov N.S. The concept of microsimulation of processes of joining dissimilar materials by plastic deformation......................................................................................................................... 36 EQUIPMENT. INSTRUMENTS Tratiya D.K., Sheladiya M.V., Acharya G.D., Acharya S.G. Economical crankshaft design through topology analysis for C type gap frame power press SNX-320.......................................................................... 50 Skeeba V.Yu., Vakhrushev N.V., Titova K.A., Chernikov A.D. Rationalization of modes of HFC hardening of working surfaces of a plug in the conditions of hybrid processing................................................................ 63 MATERIAL SCIENCE Ruktuev A.A., Yurgin A.B., Shikalov V.S., Ukhina A.V., Chakin I.K., Domarov E.V., Dovzhenko G.D. Structure and properties of HEA-based coating reinforced with CrB particles.................................................. 87 Maytakov A.L., Grachev A.V., Popov A.M., Li S.R., Vetrova N.T., Plotnikov K.B. Study of energy dissipation and rigidity of welded joints obtained by pressure butt welding................................................... 104 Singh S.P., Hirwani C.K. Analysis of mechanical behavior and free vibration characteristics of treated Saccharum munja fi ber polymer composite...................................................................................................... 117 Pribytkov G.A., Baranovskiy A.V., Korzhova V.V., Firsina I.A., Krivopalov V.P. Synthesis of Ti–Fe intermetallic compounds from elemental powders mixtures.............................................................................. 126 Singh S.P., Hirwani C.K. Free vibration and mechanical behavior of treated woven jute polymer composite............................................................................................................................................................ 137 EDITORIALMATERIALS 152 FOUNDERS MATERIALS 163 CONTENTS
OBRABOTKAMETALLOV Vol. 25 No. 3 2023 technology Simulation of the rolling process of a laminated composite AMg3/D16/AMg3 Denis Salikhyanov 1, 2, a, *, Nikolay Michurov 2, 3, b 1 Institute of New Materials and Technologies, Ural Federal University named after the first President of Russia B.N. Yeltsin, 19 Mira Str., Ekaterinburg, 620002, Russian Federation 2 Institute of Engineering Science, Ural Branch of the Russian Academy of Sciences, 34 Komsomolskaya Str., Ekaterinburg, 620049, Russian Federation 3 Ural Institute of State Fire Service of EMERCOM of Russia, 22 Mira Str., Ekaterinburg, 620062, Russian Federation a https://orcid.org/0000-0001-7235-7111, d.r.salikhianov@urfu.ru, b https://orcid.org/0000-0003-1775-6181, n.michurov@ya.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2023 vol. 25 no. 3 pp. 6–18 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.3-6-18 ART I CLE I NFO Article history: Received: 28 April 2023 Revised: 20 May 2023 Accepted: 13 June 2023 Available online: 15 September 2023 Keywords: Laminated composites Aluminum alloys Accumulative roll bonding Stress-strain state Materials bonding Finite element simulation Funding This study was performed in the frame of the grant No. 22-29-20243 “Multiscale simulation of processes of joining dissimilar materials by plastic deformation” funded by the Russian Science Foundation with the support of the government of Sverdlovsk region. Acknowledgements Research was partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Over the past decades, laminated composites based on aluminum alloys have been increasingly used in the aerospace and automotive industries. Laminated composites are usually produced by accumulative roll bonding, which results in the metallurgical bonding of initially prepared sheets. Hence, the main task of accumulative roll bonding is to obtain a reliable bond between materials. However, at present, the process of joining similar or dissimilar materials by plastic deformation is still a poorly understood phenomenon. In this regard, in recent years, methods of finite element modeling of the processes of joining materials have begun to develop intensively. The purpose of the work is to establish a relationship between stress-strain state parameters and the formation of a stable bond between aluminum alloys of different compositions. To achieve this goal, the following tasks are formulated: 1. Simulation of the laminated composite “AMg3/D16/AMg3” rolling process using data corresponding to physical experiments carried out at the Institute of Engineering Science of the Ural Branch of the Russian Academy of Sciences; 2. Selection and analysis of the most important stress-strain state parameters of the laminated composite “AMg3/D16/AMg3” rolling process. Research methods. Process simulation system Deform-3D was chosen as the main research tool. Results and Discussion. An analysis of the coordinate grid distortion and velocity vectors of material flow of layers revealed that the deformation is distributed inhomogeneously in the cross section after rolling: the outer layers flow more intensively compared to the middle layer. The maximum scatter of strain intensity ei in the cross section, observed at a maximum reduction ratio of 75%, is 12%. This allows one to accept for analytical calculations in the first approximation the assumption of deformation uniformity. A relationship is established between the beginning of the formation of a bond between composite layers and the threshold expansion of the contact surface and normal pressure at the interlayer boundary. In the final part of the study, future directions for improving the approaches of simulation the laminated composites rolling processes are proposed. For citation: Salikhyanov D.R., Michurov N.S. Simulation of the rolling process of a laminated composite AMg3/D16/AMg3. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) =Metal Working and Material Science, 2023, vol. 25, no. 3, pp. 6–18. DOI: 10.17212/19946309-2023-25.3-6-18. (In Russian). ______ * Corresponding author Salikhyanov Denis R., Ph.D. (Engineering), Associate Professor Ural Federal University named after the first President of Russia B.N. Yeltsin, 28 Mira Str., Ekaterinburg, 620002, Russian Federation Tel.: +7 (343) 375-44-37, e-mail: d.r.salikhianov@urfu.ru
OBRABOTKAMETALLOV technology Vol. 25 No. 3 2023 Introduction Over the past decades, laminated composites based on aluminum alloys have been increasingly used in the aerospace and automotive industries [1]. Due to the use of different materials in one part, it is possible to combine such properties as strength, corrosion resistance, specific weight (which is important for aviation), and thermal conductivity, etc. Laminated composites are usually produced by accumulative roll bonding, duringwhich themetallurgical joining of preliminarily prepared sheets occurs [2]. Accumulative roll bonding technology includes the following main stages: preparation of sheet surfaces to be bonded by chemical and mechanical treatment; sheets packing and fixing by welding or riveting; rolling of the pack according to the specified schedule; heat treatment; and cutting off the fixed edges of the pack. These operations can be followed by sheet stamping operations, such as cutting and drawing [2]. The principal purpose of accumulative roll bonding is to obtain reliable bonding between materials characterized by strength and evaluated through special tests [3]. However, at this moment, the joining processes of similar and dissimilar materials by plastic deformation are still poorly understood. This is confirmed by numerous works devoted to the study of the influence of individual technological factors of accumulative roll bonding on the bond strength between materials’ layers [1–10].Analysis of review [2, 4, 5], experimental [4–10] and theoretical [11, 12] works showed that the most significant factors of accumulative roll bonding are thickness reduction and pressure during rolling, surface preparation technology for joining and the ratio of strength properties of materials to be bonded. Due to the lack of reliable models for predicting the conditions under which the bonding of materials begins, the development of technologies to produce new laminated composites is accompanied by a large amount of preliminary experimental research. As shown in the previous work of the author [3], additional difficulties are caused by the unequal influence of the same factors on the process of joining materials, which depends on the combination of materials in a particular technological process. For example, in some cases, an increase in the roughness of the contact surfaces contributes to bonding; in other cases, on the contrary, it prevents bonding. To describe the mechanism of bonding of similar and dissimilar materials, there are approximately six theoretical models described in [13]. The most frequently cited model is Bay’s theoretical model of materials’ bonding [14], which describes bonding of materials as a four-stage process: (1) cracking of surface oxide films, (2) extrusion of pure metals into cracks between oxides, (3) interatomic interaction of pure metals, and (4) formation of “bonding bridges”. The limitations of Bay’s theoretical model are the assumptions typical for continuum mechanics: two-dimensional formulation, uniformity of flow of layer materials and pressures in the deformation zone, etc. In addition, Bay’s model does not allow one to determine analytically the level of deformations and pressures during rolling, which is necessary to initiate bond formation. In this regard, in recent years, methods of finite element (FE) simulation of the processes of joining materials have undergone great development [15–19]. Based on full-scale experiments, it is possible to reproduce the conditions under which bond formation between materials occurs. In particular, for the analysis of processes of materials’ bonding, such characteristics as normal pressures, shear stresses, relative average normal stresses, and effective strains are of interest. The most detailed FE analysis of the rolling process of aluminum composite was provided by Khaledi et al. [17–18]; however, they simulated the process of similar aluminum sheets bonding, which was well studied in the experimental works of Bay [14]. Study of the mechanism of bonding between dissimilar materials is a more difficult task. Therefore, the aim of this work was to establish a relationship between the stress-strain state parameters and the formation of a stable bond between aluminum alloys of different compositions. To achieve this aim, the following tasks of the work are formulated: 1. Simulation of the rolling process of the laminated composite “AMg3/D16/ AMg3” with the initial data corresponding to the physical experiments carried out at IES Ural Branch of the Russian Academy of Sciences; 2. Selection and analysis of the most important stress-strain state parameters during rolling of laminated composite “AMg3/D16/AMg3”.
OBRABOTKAMETALLOV Vol. 25 No. 3 2023 technology Research methodology The subject of research was the rolling process of laminated composite “AMg3/D16/AMg3” consisting of aluminum alloys D16 (alloy of the 2xxx series, strain- and age-hardenable) and AMg3 (alloy of the 5xxx series, strain-hardenable) [20]. Deform-3D FE modeling package was chosen as the main research tool. The simulation of the rolling process was carried out in accordance with the following conditions. Sheets with dimensions of 2.92 × 50 × 75 mm (thickness × width ×length) were considered as initial workpieces corresponding to the actual dimensions of sheets used for physical modeling. Sheets from D16 and AMg3 alloys were supplied in the annealed (soft) state. The hardening curves of these alloys were obtained using a cam plastometer of IES Ural Branch of the Russian Academy of Sciences and then integrated into the Deform 3D environment. The resulting strain resistance ratio 16 3 D AMg σ σ of the alloys was close to 0.8. Before rolling, the sheets were stacked in a pack, as shown in Fig. 1. The rolls were assumed to be ideally rigid with a linear rolling speed of 150 mm/s, and the roll diameter was 255 mm. The friction conditions corresponded to the Coulomb friction law with a friction coefficient μ equal to 0.12 between the rolls and the outer layers of the pack and a friction coefficient μ equal to 0.5 between the layers in the pack. The temperature of the pack corresponded to room one. Fig. 1. Setting of the problem of 3D FE-simulation of the laminated composites“AMg3/ D16/AMg3” rolling processes To simulate the fixation of sheets in a pack during rolling, the condition of the possibility of its mutual slipping without separation from each other is taken. The minimum size of FE for sheet workpieces, which allows one to find the convergence of the problem at iteration steps, was experimentally established: the minimum size of FE in the density window was 0.6 mm, the minimum size of FE outside the deformation zone was 1.3 mm, and the total number of FE was ~50,000 for each sheet. Thus, there were three FE per sheet thickness in the deformation zone, which can be considered satisfactory in terms of accuracy and solution time. During simulation, the thickness reduction of the pack 0 1 0 100% h h h − ε = ⋅ was varied, where h0 and h1 are the initial and final thicknesses of the pack, respectively. The reduction ε specified in the simulation corresponded to the real ones: 30, 45, 55, 65 and 75 %. At the same time, reduction of more than 45 % were
OBRABOTKAMETALLOV technology Vol. 25 No. 3 2023 performed in two passes, where the first pass was equal to 45 %, and the second one corresponded to the target final reduction (from 55 to 75 %). The authors experimentally determined that bonding between aluminum alloys occurs when the thickness reduction ε is not less than 45 %. This observation is consistent with the literature. For example, in [6], it was established that a thickness reduction of at least 40 % is required for joining sheets from commercially pure aluminum. Results and discussion Fig. 2a, b shows the shape change of the coordinate grid, which characterizes the flow of the middle layer during rolling with a reduction of 45 and 75 %, respectively. The coordinate grid was built in the central longitudinal section with a cell size of 0.5 × 0.5 mm. From the shape change of the grid, one can note that the near-surface layers of the D16 alloy flow in the longitudinal direction more intensively than the central layers of the alloy during rolling. At higher reduction ratio, as shown in fig. 2b, there is a more intensive elongation of the near-surface layers of the D16 alloy compared to the central ones. а b Fig. 2. Shape change of the central layer grid under rolling with thickness reduction ratio of 45 % (a) and 75 % (b) Fig. 3 shows the flow of metal to the exit from the deformation zone. One can note that there is a curvature of the flow velocity vectors surface of the metal layers with a lag in the flow of the central layer of D16 alloy compared to the outer layers from AMg3 alloy. In other words, the metal of the central layer is displaced toward the entrance to the deformation zone due to its lower deformation resistance. Based on this, it is obvious that the law of constancy of second volumes is not fulfilled with the corresponding distortion of the coordinate grid. To evaluate the strain inhomogeneity in the cross section of the rolled composites, the effective strain ei was measured along the line shown schematically in fig. 2. The effective strain ei was calculated as per the equation ( ) ( ) ( ) 2 2 2 1 2 2 3 3 1 2 3 i e e e e e e e = − + − + − , where e1–e3 are the principal strains. The measurement results are presented as a graph in fig. 4, where the relative thickness of the laminated
OBRABOTKAMETALLOV Vol. 25 No. 3 2023 technology Fig. 3. Surfaces of metal flow velocity vectors of layers during accumulative roll bonding with thickness reduction ratio of 45 % composite is plotted along the abscissa (0 is the lower surface of the composite, and 1 is the upper surface of the composite). In fig. 4, attention should be given to the increase in the inhomogeneity of the effective strain ei with an increase in reductions during rolling. At a low reduction ratio of 30 %, the deformation inhomogeneity across the layers is practically indiscernible, and the difference between the maximum and minimum values is 0.02. With an increase in reductions, the inhomogeneity of effective strain ei becomes more pronounced and reaches a maximum at the highest reduction of 75 %, with a difference between the maximum and minimum value equal to 0.17. It should be noted that at reductions up to 65 %, the middle layer of the composite from D16 alloy is characterized by lower values of the effective strain ei. This is consistent with the distribution pattern of the layer flow velocity vectors and the conclusion about the lag of the flow velocity of the central layer from those of the outer layers. Fig. 4. Distribution of effective strain in the cross section of composites depending on thickness reduction during rolling
OBRABOTKAMETALLOV technology Vol. 25 No. 3 2023 At a reduction ratio of 75 %, the reverse pattern is observed: the central layer of the composite is characterized by large values of the effective strain ei. This phenomenon is most likely caused by the small thickness of the sheet (2.2 mm) at this reduction ratio, which leads to a more intense propagation of the deformation into the depth of the composite. In general, the maximum scatter of the effective strain (max) (min) (max) 100% i i i e e e − is 12 %, which was observed at a thickness reduction ratio of 75 %. Therefore, it is possible to make an assumption about the uniformity of the strain distribution in the cross section of the composite “AMg3/D16/AMg3” in the first approximation for analytical calculations of the manufacturing technology. To study the conditions of the bond formation between layers from different materials, the degree of surface extend 1 0 1 A A Y A − = was calculated for different rolling options, where A0 and A1 are the initial and final surface areas [14, 21]. To determine the beginning of the bond formation in the deformation zone, the boundary criterion Y´ was set, which means the contact surface extend, at which cracks appear in the oxide layer. According to the literature sources [6, 14, 16, 17, 18, 22] devoted to the production of aluminum composites by rolling, Y´ criterion can vary from 0.3 to 0.4 for commercially pure aluminum, which is equivalent to an approximate rolling reduction ratio ε of 30–40 %. In our case, Y´ criterion was taken equal to 0.3, considering the lower ductility of the studied alloys compared to commercially pure aluminum. Fig. 5 shows the dependence of the extend of the contact surface Y at the interlayer boundary on the relative length of the deformation zone, where “0” is the entrance to the deformation zone, “1” is the exit from the deformation zone. Additionally, the same figure shows normal pressure. Analysis of the surface extend values Y at the exit from the deformation zone in fig. 5 reveals that these values practically coincide with the reduction ε values. This suggests that the influence of the lateral broadening of sheets on the contact surface extend Y is negligible and can be neglected for analytical calculations under these conditions. Fig. 5a presents the case of rolling of the three-layer pack “AMg3/D16/AMg3” with a rate of reduction equal to 30 %. As can be seen, the contact surface extend Y crosses the threshold exposure Y´ at a relative length of 0.8 of the deformation zone, which corresponds to the onset of cracking of the oxide layer and the possibility of contact between pure metals. However, at a relative length (0.8–1) of the deformation zone, normal pressures are intensively reduced from 250 to 0 MPa. Thus, the maximum relative pressure 16 D p σ is 1.5, which is not enough to create contact between the materials. Under real conditions of rolling with a reduction of 30 %, bonding between aluminum alloys does not occur, which is consistent with the computer simulation data of the presented case. Fig. 5b shows a dependence of the contact surface extend and normal pressure on the relative length of the deformation zone during rolling with a reduction of 45 %. In this variant, the achievement of the threshold value of the contact surface exposure Y´ occurs at a relative length of the deformation zone equal to 0.42. After reaching the threshold value, the contact surface continued to extend and Y reached a value of 0.45. At the relative length of the deformation zone (0.42–1), corresponding to rolling with cracks in the oxide layer, the pressure continued to increase from 320 MPa to a maximum value of 394 MPa. The relative pressures 16 D p σ in the area of the deformation zone range from 1.6 to 1.97. Since the primary bonding of materials is formed during rolling with a reduction of 45 % under laboratory conditions, it can be assumed that relative pressures from 1.6 to 1.97 are sufficient to extrude pure metals between cracks in the oxide layer and bring it to the distance of action of interatomic forces. To confirm the results of the computer simulation, the data of the microstructural study of laminated composite “AMg3/D16/AMg3” after rolling with a reduction of 45 % are shown in fig. 6. Fig. 6a presents the cross section of the composite in the area of material bonding. The bonding boundary is a visible line, with no signs of cracking or fracture of structural elements. After rolling, the laminated composite was
OBRABOTKAMETALLOV Vol. 25 No. 3 2023 technology Fig. 5. Surface expansion and pressure at the interlayer boundary during rolling of composite with reduction ratio of 30 % (a) and 45 % (b) а b subjected to a mechanical shear test to determine the bond strength, which was 43 MPa. The results of mechanical testing of the composite are presented in Table 1. The shear zone on the side of D16 alloy after testing is shown in fig. 6b, which shows characteristic “stretch lips”, indicating the cracking of oxide films, the extrusion of pure metals into cracks, and the formation of primary bonding. Similar “stretch lips” are also found in works [6, 10] devoted to the study of the bond strength between sheets from aluminum and aluminum alloys. Fig. 6b demonstrates that the “stretch lips” are located perpendicular to the rolling direction. Therefore, the cause of its appearance should be considered tensile stresses acting along the rolling direction. There are also individual particles of AMg3 alloy, which peeled off during the shear test and remained in the bond zone on the side of D16 alloy. This indicates the bonding between materials in these areas. Based on the results of computer and physical simulation, it can be seen that the primary bonding between the layer materials is achieved during rolling with a reduction of 45 %. To assess the effect of a
OBRABOTKAMETALLOV technology Vol. 25 No. 3 2023 a b Fig. 6. Cross-section of the “AMg3/D16/AMg3” composite in the bond zone (a); shear zone from D16 side after shear test (b) Ta b l e 1 Mechanical properties of “AMg3/D16/AMg3” composite after rolling with thickness reduction of 45 % Yield stress, MPa Ultimate strength, MPa Elongation, % Shear bond strength, MPa 279 292 7.2 43 further increase in the rolling reduction ratio on the bond strength, the dependences of the surface extend Y and the maximum pressure in the deformation zone pmax on reduction ratios were studied (fig. 7). It should be noted that at reduction ratio ε equal to 0.55 or more, the surface extend Y is less than reduction ratios ε, which means an increasing inhomogeneity of deformation over the thickness of composites. Fig. 7. Dependence of the surface extend Y and the maximum pressure in the deformation zone pmax on rolling reduction ratios
OBRABOTKAMETALLOV Vol. 25 No. 3 2023 technology In general, fig. 7 shows a monotonous increase in both parameters (surface extend Y and maximum pressure p), which will increase the bond strength. This conclusion is consistent with the results of experimental studies of the rolling process of aluminum and aluminum alloys [4, 6, 7, 10], where an increase in reductions led to an increase in the bond strength between materials. Based on the obtained computer simulation data, it follows that the maximum bond strength will be provided by the technological rolling route: reduction ratio in the 1st pass – 45 %; reduction ratio in the 2nd pass – 50 % (the total reduction ratio reaches 75 %). This conclusion is verified by shear tests of the composite obtained through the suggested route. The bond strength reached 67 MPa, which is 1.5 times higher than the primary bond strength obtained by the first pass of rolling. Thus, the proposed approach reflects the qualitative dependence of the bond strength on the technological factors of rolling. The problem with the proposed approach for investigating the bond formation between dissimilar materials lies in the great difficulty in establishing the threshold surface extend Y´, which should be determined for each newly developed composite. In this regard, the direction of future research should be related to the development of new models of the rolling processes of laminated composites and the development of more reliable criteria for the bond formation between dissimilar materials. Conclusions In this work, simulation of the rolling process of the laminated composite “AMg3/D16/AMg3” was performed, and stress-strain state parameters affecting the bond formation between layers were estimated. It was found that the deformation is distributed nonuniformly over the thickness of the layers during rolling: the outer layers flow more intensively than the middle layer. However, the maximum effective strain scatter of 12 % in the cross section was observed after the highest rolling reduction of 75 %. This allows us to make an assumption about deformation uniformity in the first approximation for analytical calculations. Additionally, a relationship has been established between the onset of bond formation and the contact surface extend and pressure. In the case of rolling at a reduction of 30 %, the contact surface extend reaches a threshold value close to the exit from the deformation zone, while the normal pressures drop sharply, which results in a lack of bonding. In the case of rolling with a reduction of 45 %, the contact surface extend reaches the threshold value at a relative length of the deformation zone of 0.42. In the remaining area of the deformation zone, a relative normal pressure increases from 1.6 to 1.97, which is sufficient to form primary bonding between AMg3 and D16 alloys. References 1. Williams J.C., Starke E.A. Progress in structural materials for aerospace systems. Acta Materialia, 2003, vol. 51, pp. 5775–5799. DOI: 10.1016/j.actamat.2003.08.023. 2. Ghalehbandi S.M., Malaki M., Gupta M. Accumulative roll bonding – A Review. Applied Sciences, 2019, vol. 9, p. 3627. DOI: 10.3390/app9173627. 3. Salikhyanov D. Contact mechanism between dissimilar materials under plastic deformation. Comptes Rendus Mecanique, 2019, vol. 347, pp. 588–600. DOI: 10.1016/j.crme.2019.07.002. 4. Jamaati R., Toroghinejad M.R. Cold roll bonding bond strengths: review. Materials Science and Technology, 2011, vol. 27, iss. 7, pp. 1101–1108. DOI: 10.1179/026708310X12815992418256. 5. Li L., Nagai K., Yin F. Progress in cold roll bonding of metals. Science and Technology of Advanced Materials, 2008, vol. 9, p. 023001. DOI: 10.1088/1468-6996/9/2/023001. 6. Jamaati R., Toroghinejad M.R. The role of surface preparation parameters on cold roll bonding of aluminum strips. Journal of Materials Engineering and Performance, 2011, vol. 20, pp. 191–197. DOI: 10.1007/s11665-010-9664-7. 7. Madaah-Hosseini H.R., Kokabi A.H. Cold roll bonding of 5754-aluminum strips. Materials Science and Engineering A, 2002, vol. 335, pp. 186–190. DOI: 10.1016/S0921-5093(01)01925-6. 8. Heydari Vini M., Sedighi M., Mondali M. Investigation of bonding behavior of AA1050/AA5083 bimetallic laminates by roll bonding technique. Transactions of the Indian Institute of Metals, 2018, vol. 71, iss. 9, pp. 2089– 2094. DOI: 10.1007/s12666-017-1058-1. 9. Heydari Vini M., Daneshmand S., Forooghi M. Roll bonding properties ofAl/Cu bimetallic laminates fabricated by the roll bonding technique. Technologies, 2017, vol. 5 (2), p. 32. DOI: 10.3390/technologies5020032.
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