Flow stresses of the AISIA2 tool steel Krivulje tečenja za AISI A2 orodno jeklo Tatjana Večko Pirtovsek1, Iztok Perus2, Goran Kugler1, Rado Turk1, Milan Terčelj1 1University ofLjubljana, Faculty ofNatural Sciences and Engineering, Department ofMaterials and Metallurgy, Aškerčeva cesta 12, SI-1000 Ljubljana, Slovenia; E-mail: tpirtovsek@metalravne.com; goran.kugler@ntf.uni-lj.si; rado.turk@ntf.uni-lj.si; milan.tercelj@ntf.uni-lj.si 2University ofLjubljana, Faculty ofCivil and Geodetic Engineering, Department ofCivil Engineering, Jamova cesta 2, SI-1000 Ljubljana, Slovenia; E-mail: iperus@siol.net Received: June 21, 2007 Accepted: July 10, 2007 Abstract: The hot deformation behaviour ofthe AISI A2 tool steel was examined with hot compression tests carried out in the Gleeble 1500D thermomechanical simulator in wide range of temperatures (900-1200 °C), of strain rates (0.001-10 s1) and of true strains (0-0.7). Due to the increased demands for the accuracy in predicting various parameters for the needs of optimization of hot forming technologies, it is nowadays reasonable to employ artificial intelligence for this purpose. Thus the obtained experimental database of flow stresses (curves) was used for such predictions with the CAE NN (Conditional Average Estimator Neural Network). Regardless of the scarcity of databases for strain rates (experimental data only for each decade) the mentioned approach enables to predict the flow stresses also for their intermediate states. The activation energy for the entire examined temperature range was calculated. The obtained value was compared with the reference data that had been acquired from the analysis of the hot torsion experiment. Izvleček: Termomehanski simulator Gleeble 1500D je bil uporabljen za študij toplega preoblikovanja AISI A2 orodnegajekla. Stiskalni preizkusi v vročem so bili izvedeni v deformacijskem območju 0-0,7, temperaturnem območju 900-1200 °C in hitrostih deformacije 0,001-10 s1. Zaradi povečanih zahtev po natančnosti napovedovanja krivulj tečenja za današnje potrebe optimiranja tehnologij toplega preoblikovanja, je za te namene dandanes običajna uporaba nevronskih mrež. V našem primeru smo uporabili CAE nevronske mreže s katerimi smo lahko napovedovali krivulje tečenja tudi za vmesna (nemerjena) stanja tako za temperature kot tudi hitrosti deformacije. Izračunanaje bila tudi aktivacijska energija za celotno temperaturno območje in primerjana z dobljeno vrednostjo na osnovi torzijskih preizkusov. Key words: A2 tool steel, hot compression, flow stress, CAE neural network, hyperbolic sine function Ključne besede: A2 orodno jeklo, vroče stiskanje, krivulje tečenja, CAE nevronske mreže, funkcija sinus hiperbolikus Introduction During the hot deformation many factors (Figure 1) influence the flow stresses of metal. The effects of these factors are very complex and the relationship between the flow stresses and the mentioned factors is a non-linear one, and spatially disordered^1"41. The flow stresses during the hot metal forming cannot be in all cases accurately described with phenomenological or empirical mathematical models resulting from experiments. The accuracy is still unsatisfactory and it ranges from 2 to 60 %[5-10]. Hodgson and Kong[11-12] report that the accuracy needed for the prediction of flow stresses should be within 5 % for an efficient optimization of hot rolling technologies. Physically-based models have been improved quite a lot, but they are still limited more or less to rather pure metals and are not yet used in industrial applications^131, thus the development of constitutive equations from a purely empirical basis to a more physical-basis remains an important long term scientific objective. In spite of constantly new constitutive models for describing flow stress, there has not been any substantial improvement in accuracy as far as prediction is concerned. In recent time researchers began to use BP neural networks (BP NN) as an efficient predictive tool for flow stress predictions[3-In this study we intentionally deal with the so-called CAE NN (Conditional Average Estimator Neural Network) which is, according to the author's opinion and experience, easier for use. Ma fcñft paíí mef^J-S Figure 1. Parameters influencing hot flow stress curves'-2-1 Slika 1. Parametri, ki vplivajo na tople krivulje tečenja"2-1 AISI A2 tool steel is conventionally hot forged (or hot rolled) after casting into ingots, and after the intermediate reheating the hot rolling process is continued to obtain the required dimensions. Increase of the productivity is oriented towards the hot forming of ingots with higher initial dimensions (cross sections and lengths) and toward the rolling to smaller dimensions (even below

7=1 and L -ZtPv -PmY Here, rk is the estimated (predicted) X-th output variable (e.g. stress), rnX is the same output variable corresponding to the n-th vector in the database, N is the number of vectors in the database,pni is the i-th input variable of the n-th vector in the database (e.g. temperature, strain, strain rate), pv is the i-th input variable corresponding to the vector under consideration, and L is the number of input variables. Equation 1 suggests that the estimate of an output variable is computed as a combination of all output variables in the database. Their weights depend on the similarity between the input variablesp,- of the vector under consideration, and the corresponding input variables pni pertinent to the sample vectors stored in the database. Cx is a measure of similarity. Consequently, the unknown output variable is determined in such a way that the computed vector composed of the given and estimated data is the most consistent with the sample vectors in the database. The parameter w is the width of the Gaussian function and is called the smoothness parameter. It determines how fast the influence of data in the sample space decreases with the increasing distance from the point whose co-ordinates are determined by the components (input variables) of the vector under consideration. The larger is the value of w, the more slowly this influence decreases. Large w values exhibit an averaging effect. In principle, a proper value of w should correspond to the typical distance between data points. In this case the CAE method flows a smooth interpolation of the functional relation between the input and the output variables. In some applications, as it will be shown later, a non-constant value of w flows more reasonable results than a constant value. When using non-constant w values, Equation 1 can still be used, but proper, locally estimated values of wv should be taken into account. The expression for c„ (see Equation 3) can be rewritten as ^exp >{P, PnV ' 2 w2 (4) in which different values of wv correspond to different input variables. It should be stressed that Equations lto3 were derived mathematically^18"201, based on the assumption of a constant uncertainty in the input data. The extension of the applicability of these equations to non" constant w values (Equation 4) is, however, based on physical considerations. Whereas a constant w corresponds to a sphere in an L-dimensional space (L is the number of input variables), a non-constant w value corresponds to a multi-axial ellipsoid in the same spaceb21-22d. The choice of an appropriate value of w depends not only on the distribution of data, but also on the latter's accuracy, and on the sensitivity of the output variables to change into the input variables. Some engineering judgment, based on knowledge of the investigated phenomenon, and a trial and error procedure, are needed to determine appropriate value(s) for w. Training process The originally proposed procedure[18] that is called CAE in its extended form and is presented here, consists of two parts. The first part corresponds to the so-called self-organisation of the neurons. When using relatively small databases, this part is not needed. The second part represents the mathematical description of different phenomena, using an optimal estimator, as described in previous section. From this point of view training represents a simple presentation of the data to the CAE neural network. In addition, compared to the conventional back-propagation neural networks (BP NN), testing the model is much simpler. Instead of using approximately 70 % of the data for training and the remaining 30 % of the data for testing, a different approach was used. The predicted parameter, i.e. stress of the stress-temperature-strain-strain rate curve, was predicted for each point. In this process the model vector under consideration was temporarily removed from the database. By several trials optimal values of the smoothness parameter were obtained. Recently, tests on phenomenon^281, very different from that presented here, show that such an estimation of the efficiency of the proposed model in general gives more conservative estimates than the conventional approach. To estimate quantitatively the accuracy of the CAE method for predicting the flow stress curves, the following equation, that enables calculations of the root mean sum of the squared deviations (RMSSD) for each deformation condition, is used: RMSSD 10 rk~rk) (5) N The prediction is considered good if the RMSSD value is within 5 % of the mean flow stress for that experimental condi-tionb11-12d. The mean flow stress <7m/s is calculated according to m/s 1 \ = 0,03). Strain Discussion Imbert and McQueenb14"15d carried out hot torsion tests on a material of the same grade. These authors obtained somewhat lower values for the flow stress curves. This was expected, since flow stress curves were obtained with torsion tests. The reasons for this discrepancy were firstly a slightly different chemical composition of the tested material, though it was still within permitted limits for the given grade, secondly a different initial microstructure, further, unstable testing conditions, and finally a different heat generation the during deformation of the two types of tests. The constants were calculated from the maximum flow stresses for different temperatures and strain rates with the hyperbolic sine equation^23"251 Z = eexpR / RT ) = A(sinha