Contents. List of Contributors Preface XV. Part I Concepts 1

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1 V List of Contributors Preface XV XI Part I Concepts 1 1 Introduction 3 Georg J. Schmitz and Ulrich Prahl 1.1 Motivation What Is ICME? The Unaries : I, C, M, and E The Binaries ME, IM, IE, IC, CE, and CM The Ternary Systems : CME, ICM, IME, ICE The Quaternary System: ICME Historical Development of ICME Current Activities Toward ICME Toward a Modular Standardized Platform for ICME Scope of This Book 17 References 18 2 Basic Concept of the Platform 21 Georg J. Schmitz and Ulrich Prahl 2.1 Overview Open Architecture Modularity Individual Modules Bridging the Scales Interface Modules/Services Data Modules Standardization Web-Based Platform Operation Benefits of the Platform Concept Benefits for Software Providers Benefits for Industrial Users 38

2 VI Benefits for Academia, Education, and Knowledge Management Verification Using Test Cases 39 3 State-of-the-Art Models, Software, and Future Improvements 43 Markus Apel and Georg J. Schmitz 3.1 Introduction Overview of Existing Models and Software Requirements for Models and Software in an ICME Framework Model Quality Improving Numerical and Model Accuracy Speeding Up Individual Models and Distributed Simulations Information Integrity Benefits of Platform Operations for Individual Models Improved Quality of Initial Conditions Improved Quality of Materials Data Consideration of Local Effective Materials Properties Strong and Weak Coupling of Platform Models Conclusions 59 References 59 4 Standardization 61 Stefan Benke and Georg J. Schmitz 4.1 Overview Standardization of Geometry and Result Data Extended File Header Geometric Attributes Field Data Material Data Application Programming Interface USER MATERIAL TM Subroutine USER MATERIAL HT Subroutine USER EXPANSION Subroutine USER PHASE CHANGE Subroutine Future Directions of Standardization 78 References 79 5 Prediction of Effective Properties 81 Gottfried Laschet, Tatyana Kashko, Stephan Benke, Mehmet Öte, and Kirsten Bobzin 5.1 Introduction Homogenization of Materials with Periodic Microstructure Static Equilibrium of a Heterogeneous Material Periodicity and Two-Scale Description The Asymptotic Homogenization Method Homogenization of Materials with Random Microstructure 88

3 VII Morphology Analysis and Definition of the RVE Influence of the RVE Position on the Effective Elastic Properties Stochastic Homogenization Postprocessing of Macroscale Results: the Localization Step Dedicated Homogenization Model: Two-Level Radial Homogenization of Semicrystalline Thermoplastics Mechanical Properties of the Amorphous and Crystalline Phases Virtual Material Testing Tools for the Determination of Effective Properties Homogenization Tool HOMAT and Its Preprocessor Mesh2Homat Program Environment for Virtual Testing Examples Methods Comparison Based on a Benchmark Austenite Ferrite Phase Transformation of a Fe C Mn Steel Application of the Stochastic Homogenization: Effective Thermal Conductivity of an Open-Cell Metallic Foam Conclusions 112 References Distributed Simulations 117 Thomas Beer, Tobias Meisen, and Rudolf Reinhard 6.1 Motivation The AixViPMaP Simulation Platform Architecture Data Integration Web-Based User Interface for the Simulation Platform 125 References Visualization 131 Thomas Beer and Tobias Meisen 7.1 Motivation Standardized Postprocessing Integrated Visualization Data History Tracking 139 References 140 Part II Applications Test Case Line Pipe 145 Patrick Fayek, Hendrik Quade, Thomas Henke, Gottfried Laschet, Markus Apel, Eduardo Sambrano Rossiter, Markus Bambach, and Ulrich Prahl 8.1 Introduction Materials Process Overview of Process Chain 147

4 VIII Reheating Hot Rolling Cooling and Phase Transformation U- and O-Forming Welding Experiments Dilatometer Experiments Compression Tests to Determine Flow Curves and DRX Kinetics Tensile Tests Welding Experiments Experimental Process Chain Simulation Models and Results Reheating Hot Rolling Cooling and Phase Transformation U- and O-Forming Welding Conclusion and Benefits 183 References Test Case Gearing Component 187 Sergey Konovalov, Thomas Henke, Ulrich Jansen, Ario Hardjosuwito, Wolfram Lohse, Markus Bambach, and Ulrich Prahl 9.1 Introduction Materials The Process Chain Overview Hot Rolling and Forging FP Annealing Machining Carburizing Laser Welding Experimental Procedures and Results Overview of Phenomena Characterization of Dynamic Recrystallization and Grain Growth Characterization of Phase Transformations Investigation of the Particle Evolution along the Process Chain Characterization of Welding Depth Simulation Chain and Results Overview of Simulation Chain Macroscopic Process Simulations Microscopic Simulations Conclusions 217 References 218

5 IX 10 Test Case: Technical Plastic Parts 221 Walter Michaeli, Christian Hopmann, Thomas Baranowski, Gottfried Laschet, Barbara Heesel, Tim Arping, Kirsten Bobzin, Tatyana Kashko, and Mehmet Öte 10.1 Introduction Material Polypropylene Process Chain Modeling of the Phenomena along the Process Chain Crystallization of Semicrystalline Thermoplastics Formation of Molecular Orientations Effective Mechanical Properties of Semicrystalline Thermoplastics Macroscopic Mechanical Materials Behavior Implementation of the Virtual Process Chain SigmaSoft SphaeroSim HOMAT Abaqus FEA Simulation Chain Experimental Methods Results Macroscopic Process Simulation Microstructure Simulation Effective Mechanical Properties Macroscopic Part Behavior Summary and Conclusion 253 References Textile-Reinforced Piston Rod 257 Britta Kuckhoff, Josef Klingele, Markus Linke, Thomas Gries, Kirsten Bobzin, Thomas Schläfer, Tatyana Kashko, and Mehmet Öte 11.1 Introduction Experimental Process Chain The Braiding Process The Investment Casting Process Simulation Chain Overview Simulation of the Braiding Process Simulation of the Braiding Structure Simulation of the Infiltration Process Simulation of the Solidification Microstructure Effective Anisotropic Material Properties Effective Properties of the Component Conclusion/Benefits 277 References 278

6 X 12 Test Case Stainless Steel Bearing Housing 281 Stephan Freyberger, Stefan Benke, Hendrik Quade, and Jenny Rudnizki 12.1 Introduction Materials Overview Thermophysical Properties Processes Overview of the Process Chain The Casting Process The Heat Treatment Process The Machining Process The Application Phenomena Overview of Phenomena to Be Modeled Description of the Individual Phenomena Simulation Chain Simulation Tools Simulation Flowchart Results Macroscopic Process Simulations Microstructures Conclusions/Benefits 303 References Future ICME 305 Ulrich Prahl and Georg J. Schmitz 13.1 Imperative Steps Lessons Learned Future Directions Education and Training Internationalization, Professionalization, and Commercialization Platform Development Closing Remark 320 References 321 Index 323