Reinforcing steel bars (rebars) are widely manufactured using the Tempcore™ process. Several studies have been conducted analyzing the effect of the heat treatment route on the strength and corrosion resistance of rebars, but knowledge of its effects on the residual stresses of the finished product are largely lacking. This paper presents experimental investigations to identify the material parameters necessary to simulate the Tempcore™ process using thermo-elasto-plastic constitutive modeling in order to study the generation of residual stresses during the manufacturing process. Mechanical parameters such as yield strength at elevated temperatures and elastic constants were determined experimentally. A continuous cooling transformation diagram needed to model the phase transformations was also identified and is presented here. Residual stress distributions in the surface region of the rebar were characterized using X-ray diffraction. Further characterizations of microstructure, chemical composition, and hardness were carried out. The constitutive modeling approach for the numerical simulation is briefly described for which the experimentally determined parameters are required as input.

Ribbed reinforcing steel bars (rebars) are used for the reinforcement of concrete structures. In service, they are subjected to cyclic loading. Several studies addressing the relationship between rib geometry, stresses at the rebar surface induced by service loads and the rebar fatigue performance can be found in literature. However, the rebar’s fatigue performance is also influenced by residual stresses originating from the manufacturing process. In this contribution, a modeling approach is proposed to examine geometrically and thermo-mechanically induced stress concentrations in ribbed reinforcing bars made of the steel grade B500B. A linear-elastic load stress analysis and a thermo-mechanical analysis of the manufacturing process are conducted. The results are discussed and compared to literature results. In case of the load stress analysis, the results agree well with findings reported in literature and extend the current state of knowledge for B500B rebars with small diameters. In case of the thermo-mechanical analysis, compressive residual stresses at the rebar surface between two ribs and tensile residual stresses in the longitudinal direction at the tip of the ribs can be reported.

Thermomechanical treatments involving solid-state phase transformations play an important role for the manufacturing of functional and reliable components in many engineering applications. Accordingly, numerical investigation and optimization of such processes require considering thermoelastoplasticity under the influence of ongoing transformations and in particular the impact of transformation-induced plasticity (TRIP). While a number of elaborate plasticity models have been proposed for the description of TRIP, none of them seem to have received much prevalence in applications due to their complexity or hard to determine model parameters. Instead, the overwhelming majority of applied research either relies on simplistic formulations dating back to early phenomenological approaches or neglects TRIP altogether. In this work, we therefore provide an accessible, straightforward and easy-to-implement solution scheme for the TRIP model proposed by Leblond et al. which, despite being widely recognized, is hardly ever employed in full form. Specifically, we employ implicit backward-Euler integration and an elastic–plastic operator split approach to update the stresses in order to obtain a simple and concise algorithm for which we then derive the corresponding consistent tangent modulus. Furthermore, the work contains an application of the solution scheme to a symmetrically cooled plate and an in-depth discussion of the influence of TRIP by means of this tractable numerical example. Specifically, we highlight the discrepancies arising in transient and residual stresses and strains compared to the conventional $$J_2$$J 2 -plasticity approach where the phase transformation is accounted for merely by adapting the yield strength of the compound.

The residual stress approximation methods formulated by McDowell and Moyar, Jiang and Sehitoglu, and McDowell for rolling and sliding contact problems are reconsidered in the context of single anisothermal loading cycles and isotropic hardening. A consistent extention to incorporate thermal softening is developed and the generalized thermoelastoplastic algorithms are cast into a proper predictor–corrector formulation. Detailed explicit and implicit numerical integration strategies are presented and validated using specifically designed finite element models that conform to the underlying mechanical assumptions. Then, the applicability of the approximate algorithms to anisothermal problems with isotropic hardening and thermal softening is analyzed by assuming a rate-independent Johnson–Cook-type yield stress model and by comparing the obtained transient and residual stresses to results from full-scale finite element half-space models under varying loading and strain-hardening intensities. An in-depth, comparative discussion on the adequacy of the algorithms in conjunction with the justification of their respective mechanical simplifications follows. Sufficiently strong strain hardening is found to be a prerequisite for accurate predictions, and Jiang and Sehitoglu’s approach is deemed to be preferable for the considered type of problem. The conclusions drawn from the investigations are discussed in the context of common applications with particular emphasis on manufacturing process modeling and the corresponding guidelines are proposed for such use cases.