Research on securing the formability of aluminum 7000 series 3D printing alloy and optimizing heat treatment through adding Zr inoculant and refining crystal grains to achieve high strength and elongation of body structure

Hyomoon Joo (Hyndai Motor Group)

Solidification cracks caused by columnar grains in precipitation-hardenable Al alloys such as 7000 series limits the applicability of laser-based-3D printing. Recently, cracking has been effectively reduced by introducing equiaxed grains through inoculant addition to Al alloy powder. However, the mechanisms through which equiaxed grains can prevent cracking have not been explained from the viewpoint of both microstructure and process parameters. In this study, a solidification cracking model was proposed using the parametric L-PBF results of ZrH2 particle-added A7075, where equiaxed grains were formed as a function of energy density. Through this, we aimed to achieve high strength of body parts.

Investigation of the Modeling on Crush FEM of Aluminium Components

Shingo Nakajima･Ryohei Yukishige (Kobelco Reseach Institute)

Falling-weight tests were performed on test specimens of aluminum cast components to obtain load behavior and deformation behavior. Additionally, simulations of the fallling-weight tests were conducted using FEM and compared with the test results. In the FEM analysis, the effects on load behavior and deformation behavior were investigated by examining the modeling methods for element types, material properties, and variations in fracture characteristics.

Advanced numerical method for weight optimization under consideration of integrated and innovative design trends

Jan Ophey (FEV Vehicle GmbH)･Michael Hog (FEV Group)･Noriyuki Muramatsu (FEV Japan)･Max Krause･Christian Kuerten (FEV Vehicle GmbH)

Giga casting - the start of the revolutionary trend of integral design in the body-in-white for decades, with the aim of reducing the number of parts, streamlining the production process and minimizing development and production times. Integral design is not limited to Giga casting but also leads to new concepts for a variety of materials and approaches. Hand in hand, comes a need for advanced numerical optimization methods which enable a holistic CAE-based weight reduction. By optimizing shape, material and thicknesses such an approach is established and performed on a representative integral design part.

Process improvement of structural strength development using AI Surrogate Models

Mikimasa Kawaguchi･Motoki Tanaka･Takashi Ebisugi･Toru Nakano･Jun Nishikawa (Mazda)･Bisser Raytchev (Hiroshima University)

In MBD for structural strength development, it is essential to identify optimal solutions for conflicting functions. However, the lengthy timeframes associated with model creation and computation present a challenge in the early stages of development. This study introduces an optimization study technique that employed machine learning. These findings will be employed to determine the configuration during the early stage of the next-generation power source’s development.

Development of crashworthiness evaluation method using simplified test structures and verification of fracture prediction technology

Takahiro Aito･Takeshi Kawachi･Eriko Shimoda (NIPPON STEEL CORPORATION)

We developed a test method that can reproduce the collision deformation mode of the front side member in a simple hat-shaped structure. It is possible to express the difference in the occurrence of material fracture due to the bending property of high strength steel sheet, and the difference in the occurrence of spot weld fracture due to spot welding conditions. In addition, the accuracy of the fracture prediction technology using FEM analysis was verified.