Achieving uniform temperature within the effective gauge length in thermo-mechanical testing is crucial for obtaining accurate material data under hot stamping conditions. A new grip design for the Gleeble Materials-Simulator has been developed to reduce the long-standing problem of temperature gradient along a test-piece during thermo-mechanical tensile testing. The grip design process comprised two parts. For the first part, the new design concept was analysed with the help of Abaqus coupled Thermal-Electric Finite element simulation through the user defined feedback control subroutine. The second part was Gleeble thermo-mechanical experiments using a dog-bone test-piece with both new and conventional grips. The temperature and strain distributions of the new design were compared with those obtained using the conventional system within the effective gauge length of 40 mm. Temperature difference from centre to edge of effective gauge length (temperature gradient) was reduced by 56% during soaking and reduced by 100% at 700 °C. Consequently, the strain gradient also reduced by 95%, and thus facilitated homogeneous deformation. Finally to correlate the design parameters of the electrical conductor used in the new grip design with the geometry and material of test-piece, an analytical relationship has been derived between the test-piece and electrical conductor.
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