MAE612: Materials Processing: Theory and Applications
Cornell University, Fall 2001
- Stress definition, stress transformations, plane stress, equilibrium equations and deviatoric
stress components (review lecture) pdf
- Small strain and logarithmic strain definitions, plain strain conditions, strain transformations, linear elasticity (review lecture) pdf
- Introduction to work hardening, plastic instability pdf
- Macroscopic plasticity, yield criteria pdf
- Ideal work method for the analysis of deformation processes, slab analysis for extrusion and drawing processes pdf
- Slab analysis for flat rolling and forging processes pdf
- Upper bound analysis pdf
- Sheet bending processes, springback, forming limit diagrams pdf
- Plastic anisotropy pdf
- Cup drawing, earing pdf
- Strain rate and temperature effects on flow stress pdf
- State variable approach to inelastic behavior pdf
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- Introduction to thermodynamics of materials: First and second laws, equilibrium conditions for
multi-component, multi-phase alloys pdf
- Heat flow in solidification, Stefan problems pdf
- Solidification of binary alloys, morphological instabilities pdf
- Solidification microstructures, microsegragation, undercooled melts pdf
- Cellular solidification pdf
- Plane front solidification of polyphase alloys, eutectic growth pdf
- Melt flow pdf
- Thermodynamics of solidification pdf
- Nucleation and interface kinetics pdf
- Defects in castings pdf
- Solidification process design and control pdf
- Volume averaging techniques and other modeling issues pdf
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Basic course infoCredit: 4 Units.
Lectures: Tues./Thurs. 2:55 -- 4:10, Upson 102.
Professor: Nicholas Zabaras,
188 Frank H. T. Rhodes Hall, (607) 255-9104, firstname.lastname@example.org
Office hours: Tuesdays 3:00 -- 4:00 p.m.; Fridays 3:00 -- 4:00 p.m.
References: The course lectures are
available on the course web site. Important reference
These books will be on reserve in the Engineering library and you will need
to periodically consult them to supplement the lecture notes and to find support material for your
References on Deformation Processing:
- S. Kobayashi, S.-I. Oh and T. Altan, Metal forming and the finite-element method
- W. F. Hosford and R. M. Caddell, Metal forming : mechanics and metallurgy
- R. H. Wagoner and J.-L. Chenot, Fundamentals of metal forming
- J.C. Simo and T.J.R. Hughes, Computational Inelasticity
- J. Bonet and R.D. Wood, Nonlinear continuum mechanics for finite element analysis
- J. Lubliner, Plasticity theory
- W. F. Hosford, The mechanics of crystals and textured polycrystals
- D. C. Stouffer and L. T. Dame, Inelastic deformation of metals: models, mechanical properties, and
References on Solidification Processing:
- M. C. Flemings, Solidification processing
- W. Kurz and D.J. Fisher, Fundamentals of solidification
- W. M. Deen, Analysis of transport phenomena
- G. H. Geiger and D. R. Poirier, Transport phenomena in metallurgy
- S. H. Davis, Theory of solidification (due in October, 2001)
Homework: assigned each Thursday and
due the following Thursday in the beginning of the class. We
will not accept late homework. You are allowed, even encouraged,
to work on the homework in small groups, but you must write up your own homework
to hand in.
Grading: Homework 50% and Project 50%.
Prerequisites: Previous knowledge of Mechanics of Materials, Heat Transfer,
Thermodynamics and Fluid Mechanics will be useful in appreciating the course material. Students
will be allowed to concentrate on the Deformation or Solidification related topics of the course depending
on their interests and background.
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Course descriptionThis graduate course covers only a few selective topics
in deformation and solidification processing. Even though no attempt will be made to cover all
aspects of such processes, each student will be allowed as part of the course project
to work in depth in
a particular area of material processing that is mutually agreeable. Some of the topics to
be covered include:
Basic principles governing the inelastic behavior of solids. Work hardening, strain rate and temperature
dependence of material response. Multiaxial plasticity and creep. State variable approach to constitutive modeling.
Slab-analysis models and bound theorems for problems of forging, extrusion,
and rolling. Ideal forming techniques. Analysis of sheet-metal forming including
limit diagrams and springback. Defect initiation during forming processes.
Multi-stage deformation process design.
Directional solidification processes. Morphological instability
of a solid/liquid interface, solidification microstructures,
solute redistribution, micro- and macro-segregation.
Thermomechanical defects in casting processes. Eutectic microstructures. Melt flow effects
on solidification microstructures. Continuum mushy-zone models. Phase field methods.
Catalog description: Basic principles governing
the inelastic behavior of solids. Slab-analysis models and
bound theorems for problems of forging, extrusion, and
rolling. Analysis of sheet-metal forming including limit
diagrams and springback. Defect initiation during forming
processes. Basic solidification processes. Morphological
instability of a solid/liquid interface, solidification
microstructures, solute redistribution, microsegregation,
and macrosegregation. Thermomechanical defects in casting
processes. Rapid solidification
microstructures. Behavior and forming of metal alloys in the semisolid state.
Intended audience: Graduate
Students in Mechanical
and Aerospace Engineering, Masters of Engineering students and MAE/MSE seniors (with permission of instructor).
- to review the mechanical properties of materials and their effect on materials processes
- to expose students to basic deformation processing techniques for controlling shape
and properties in the final product
- to review the fundamentals of solidification and the various forms of solidification microstructures
- to review directional solidification processes and analytical techniques for their analysis
- to provide a review of various physical mechanisms (diffusion, melt flow, etc.) and their effects
on the solidification microstructures
- to provide modern methods for the design and control of solidification and crystal growth processes
- to give students the background required to pursue further graduate studies in
deformation/solidification processing and related materials processes
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- Review of the Mechanics of Materials
- Stress components, principal stresses, stress
transformations, Mohr circle for stress.
- Stress equilibrium.
- Stress decomposition in deviatoric and hydrostatic parts.
- Small strain components, strain transformations,
Mohr circle for strain,
- Linear elasticity, elastic stress-strain relations, elastic strain energy.