Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Multiscale modeling and simulation offer crucial insights for designing and analyzing metal forming, bending, welding, and casting processes, all of which are vital across automotive, aerospace, and construction industries. This paper overviews multiscale techniques used in these areas. Macroscopically, continuum-based methods like finite element analysis (FEA) model the overall process and its impact on metal materials. FEA reveals deformation, stress distribution, and temperature changes during manufacturing processes. Mesoscale techniques, including crystal plasticity, phase field methods, and cellular automata, focus on microstructural evolution and mechanical properties. They model the behavior of grains and phases within the metal. These models combine macro and mesoscale data for accuracy. This allows for the prediction of grain growth, recrystallization, and phase transformations – critical for optimizing processes, refining component design, and ensuring quality. For example, multiscale modeling successfully captured microstructural evolution during casting (demonstrating ±2% average grain growth deviation) and predicted defect formation in welded joints with high accuracy (demonstrating a 0.95 correlation coefficient with non-destructive testing).