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The present work concerns the simulation of metallurgical evolutions in 3D multi-pass forming processes. In this context, the analyzed problem is twofold. One point refers to the management of the microstructure evolution during each pass or each inter-pass period and the other point concerns the management of the multi-pass aspects (different grain categories, data structure). In this framework, a model is developed and deals with both aspects. The model considers the microstructure as a composite made of a given (discretized) number of phases which have their own specific properties. The grain size distribution and the recrystallized volume fraction distribution of the different phases evolve continuously during a pass or inter-pass period. With this approach it is possible to deal with the heterogeneity of the microstructure and its evolution in multi-pass conditions. Both dynamic and static recrystallization phenomena are taken into account, with typical Avrami-type equations. The present model is implemented in the Finite Element code FORGE2005®. 3D numerical simulation results for a multi-pass process are presented.

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We present a mathematical method for identifying, separating and quantifying the 3D significant distortions. Measurement of a gas quenched C-ring type sample is performed by a Coordinate Measuring Machine (CMM). Quenching simulation is done with the commercial software Forge 2008 TTT®. After comparisons, we notice that the distortions and their tendencies are the same but not exactly the amplitudes. We only focus on distortions which have a physical origin, like the pincers opening, often observed in the literature. As a first explanation, we underline the role of phase transformations and volume dilatation of the steel during quenching.