A multi-length scale sensitivity analysis for the control of texture-dependent properties in deformation processing

Material property evolution during processing is governed by the evolution of the underlying microstructure. We present an efficient technique for tailoring texture development and thus, optimizing properties in forming processes involving polycrystalline materials. The deformation process simulator allows simulation of texture formation using a continuum representation of the orientation distribution function. An efficient multi-scale sensitivity analysis technique is then introduced that allows computation of the sensitivity of microstructure field variables such as slip resistances and texture with respect to perturbations in macro-scale forming parameters such as forging rates, die shapes and preform shapes. These sensitivities are used within a gradient-based optimization framework for computational design of material property distribution during metal forming processes. Effectiveness of the developed computational scheme is demonstrated through computationally intensive examples that address control of properties such as Young’s modulus, strength and magnetic hysteresis loss in finished products.