Papers by Keyword: Bulging

Abstract: There is a large body of literature on both the techniques for bulge testing and experimental results for various metallic materials (see the book of Banabic [1]). Generally, the experimental data for isotropic materials are interpreted using the von Mises yield criterion [2]. In this paper, we investigate the role played by the third invariant of the stress deviator, on the response under bulging of isotropic materials that have the same mechanical response in tension and compression. To this end, we use the yield criterion developed by Cazacu [3] and our implementation of this model in the F.E. code Abaqus [4]. For isotropic materials, this yield criterion involves a unique parameter, denoted ; in the case when it reduces to the von Mises yield criterion while for it involves dependence on . The results of F.E. simulations of bulge tests for isotropic materials characterized by various values of the parameterput into evidence new aspects concerning the stress states experienced by the respective materials under bulging.

Abstract: In this work the durability assessment and the permanent deformation of a copper mold for continuous casting of steel have been investigated using mathematical models based on the Finite Element method. The cyclic plasticity behavior of the material is represented by a combined kinematic-isotropic model experimentally validated. Results from thermo-mechanical analysis are in good agreement with measurements. In particular, creep effects included into the model permit the evolution of bulging near the meniscus area to be correctly predicted. A life estimation is performed considering strain-life and stress-rupture time curves according to a cumulative damage law.

Abstract: Present investigation pertains to establish the bulging characteristics of sintered steel preforms under cold upsetting. Cylindrical preforms of Fe-0.8%C and with 1%Mo and 2%Mo of 86% initial theoretical density and 0.4 initial aspect ratio have been produced through conventional powder metallurgy techniques. These preforms were further subjected to secondary deformation, that is, cold upsetting under nil and zinc stearate lubricant conditions. The results obtained from this experiment were used to study the bulging characteristics with densification and hoop stress. An empirical equation is determined between these parameters and is found to follow a power law relationship.

Abstract: During production of rolled steel strips the quality of the surface of finished strips influences steel consumption considerably. The most critical areas for crack formation during rolling are lateral sides of slabs. Deformation behaviors of the slab edge in roughing rolling process were analyzed by the finite element method with Deform-3D. In this study our focus is the analysis of the influence of edger’s form on the possibility to decrease surface cracking during roughing hot rolling.

Abstract: Working principle and advantages of tube in hydroforming with radical crushing were described and introduced briefly. The research status of deformation behaviors of tube in hydroforming with radical crushing with the tube cross-section shape was made into triangle, rectangle or trapezoid were reviewed in this paper. Finally, the development trend and burning questions of tube in hydroforming with radical crushing were predicted.

Abstract: To enhance the heating efficiency and the formability of AZ31 magnesium alloy, the assistance heating method is adopted during the hot bulging process. The free bulging test of coarse grained and fine grained AZ31 magnesium alloy sheet was carried out. During the forming process, the effects of pulse current on the formed sheet combine both thermoelectricity and electro-plasticity. Directional and asymmetrical deformation of the coarse-grained AZ31 magnesium alloy sheet by the effect of pulse current is observed and analyzed. But in the same processing condition, the deformation of fine grained AZ31 magnesium alloy sheet is symmetrical. To investigate the influence of electron wind force on pulse current auxiliary bulging process, the simulation of AZ31 magnesium alloy pulse current auxiliary bulging based on the electron wind force value calculated by mathematical model was performed using the Marc software. The bulging simulation result showed a special phenomenon that the shape of the bulging specimen is unsymmetrical and the dome deviated from the symmetry axis to the side of positive pole. The simulation results were basically consistent with the experimental results. The deformation properties, microstructure characteristics, dislocation movement of the AZ31 magnesium alloy during gas bulging processing by the pulse current are investigated.

Abstract: For enhance the heating efficiency and the formability of the magnesium alloy and aluminium matrix composite sheets, pulse current is adopted to the gas bulging and stamping processes. During the bulging process of magnesium alloy sheet, the effects of dynamic pulse current on the formed sheet combine both thermoelectricity and electro-plasticity. The effect and the applicability of the pulse current heating have been evaluated. The deformation properties, microstructure characteristics, and dislocation movement of the AZ31 alloy sheet during bulging process by the resistance heating are investigated. And the resistance heating has been adopted to improve the formability of SiC_p/2024Al composites in stamping process. The pulse current density achieved 21.7A/mm² and temperature of SiC_p/2024Al composite correspondingly reached to around 400°C in the 50s. The results showed that stainless steel inserts between sheet and copper electrodes successfully prevented the heat dissipation and promote temperature uniformity over the sheet during electrifying. In addition, workpiece formed by the pulse current deep drawing shows better shape retention, surface quality and high geometry dimensional accuracy.

Abstract: Fine blanking is a press-working process that permits the production of precise finished components which are cleanly sheared through the whole cutting surface. It can be eliminated secondary operations, such as milling, grinding, etc. Recently, many studies on the weight reduction of automobile for fuel saving were underway. Especially, there are many examples in which light metal like Al were applied for automotive parts. The clearance between the punch and die of a fine blanking tool is an important design factor that affects the sheared surface of a product. In a fine blanking process, the clearance is typically assigned a 0.5% material thickness. If the clearance is too big, a fractured surface would occur in the product while if it is too small, bulging would occur. In this study, a setting for optimum clearance was proposed for inner corner shapes by checking shear characteristics and bulging effects according to various clearances. After designing a special part with various corner shapes possessing Al5052 (thickness: 4 mm), a fine blanking tool was constructed and fine blanking experiments were conducted. The result could be usefully applied in fine blanking processes for Al automobile parts with corner shapes in the future.

Abstract: Recent advances in continuous casting have facilitated remarkable improvement in the quality of cast steel. The focus of the present paper is directed towards understanding of the influence of chemistry and intrinsic solidification behaviour on the different quality issues of stainless steel. An attempt has been made, wherever possible in quantitative terms , to correlate the chemistry and the process parameters with the quality factors. The relevant theoretical background has been touched upon. Understanding has been developed on the role of the ratio of nickel equivalent and chromium equivalent. This factor can be used to represent the chemistry of any stainless steel grade. Under similar casting conditions, specific problem of mould sticking , strand bulging , or depression formation has been explained invoking this chemistry factor. Each quality issue owes its genesis to interaction between the high-temperature strength and ductility of the solidifying shell during casting. The important roles of micro-segregation , the effective shell thickness during the early stage of casting , and the temperature range of transformation for δ-ferrite to austenite have been highlighted. An approach of grade-specific casting practice has been suggested to formulate the specific casting parameters. The developed understanding has been utilised to address specific quality problems in continuously cast slabs and rolled products of different stainless steel grades. This integrated understanding can be useful for ensuring the quality of stainless steel of any chemistry.

Abstract: Fine blanking is a press-working process that permits the production of precise finished components which are cleanly sheared through the whole cutting surface. It can be eliminated secondary operations, such as milling, grinding, etc. Recently, many studies on the weight reduction of automobile for fuel saving were underway. Especially, there are many examples in which light metal like Al were applied for automotive parts. Eco-Al is the new material which is replaced Mg of aluminum alloy with Mg+Al2Ca, therefore Eco-Al material has improved mechanical properties and formability. The clearance between the punch and die of a fine blanking tool is an important design factor that affects the sheared surface of a product. In a fine blanking process, the clearance is typically assigned a 0.5% material thickness. If the clearance is too big, a fractured surface would occur in the product while if it is too small, bulging would occur. In this study, a setting for optimum clearance was proposed for inner corner shapes by checking shear characteristics and bulging effects according to various clearances. After designing a special part with various corner shapes possessing Eco-Al5052 (thickness: 4 mm), a fine blanking tool was constructed and fine blanking experiments were conducted. The result could be usefully applied in fine blanking processes for Eco-Al automobile parts with corner shapes in the future.