J. Cai, Caterpillar Inc., Mossville, IL

Summary: In producing a large steel component, various manufacturing processes lead to non-uniform microstructure and possible defects within a part. This microstructure and component soundness greatly influences component structural performance and life. Numerical simulation provides a means for understanding process parameter effects on material behavior and defect formation during a given manufacturing process. This paper focuses on applications of multiscale numerical models for prediction of component loading capabilities and failure mechanisms. The proposed numerical model integrates a heat treat simulation model, an explicit microstructure based damage model and structural performance analysis. The results show good agreement with experimental data obtained during component testing. By using an integrated multiscale modeling approach, component design and process development time could be greatly shortened with high confidence in component performance.