Papers by Keyword: CAE

Abstract: In Engineering Schools, labs for teaching forming processes by means of material conservation methods are generally equipped with the appropriate equipment and tools to exemplify the theory received in class. However, the use of simulation techniques to complement the formation is not usually widely extended, since their learning is not usually trivial.One of the material conservation forming processes is sand casting. This process is of great educational significance, since the theory that defines it sets the basis for understanding other related moulding processes. In this context, the use of simulations of the moulding process allows the visualization of practical examples, helping to explain more clearly the theoretical information explained in class.Therefore, in this research a simulation assisted analysis has been developed using the Inspire Cast by Altair software, of teaching parts made in sand casting. First of all, students have been shown by means of simulations, the defects that can be originated in a part manufactured by sand casting. The study has been carried out by redesigning the risers involved in the distribution system of the process, by means of the Chvorinov's rule.Finally, a series of conclusions have been achieved, among which the following one stands out: if the functional performance of the part manufactured by sand casting is to be taken into account, the cooling modulus criterion must be selected for the design of the riser. Although, in principle, the material required for moulding is much larger, the defects generated in the part will be considerably reduced.

Abstract: Brittle materials such as ceramics, glass or single-crystal silicon are extensively used for industrial applications and recently become an object of actual research due to the development of new products and technologies. In cases, where special attention is paid to the surface layer, mechanical processing with a diamond tool is of interest as one of the most efficient technology to manufacture products from brittle materials. In this paper, simulation method is presented, which allows to estimate an effect of cutting force on the size of defects zone formed in a hard brittle plate during machining. In the proposed model, there is a distinguished surface layer, which can have its own unique properties that differ from the properties of the brittle plate. In this work, the ANSYS finite element program is used to simulate the technological processes and solve the problem of stress distribution in a quasi-static formulation.

Abstract: This study used cold forging to produce car components with the desired hardness without using postprocessing methods such as heat treatment, surface blasting, and polishing. Material diameter, mold neck diameter, and hardness of the material after annealing were used as parameters, and nine sets of experimental parameters were obtained using the Taguchi method. Under the premise of high-quality forging, this study determined the optimal hardness and the relationship between formation parameters and forging hardness. By inputting the hardness data obtained from the Taguchi L9 orthogonal array into a Matlab-implemented neural network, this study determined a hardness formula. Finally, using the inbuilt graphical user interface software of Matlab, a simple program was written that can be used to predict hardness and that could extensively reduce the costs and time associated with forging development.

Abstract: The chassis is the backbone of all automobiles. In passenger cars and buses, the chassis forms the basic shape of the vehicles and ensures the safety of passengers as well as transported goods. Most chassis have the frame structure and is manufactured using stamping and cold rolled technology to enhance the required rigidity. One of the most important criteria that chassis manufacturers consider during the design process is structural integrity: preventing failure while optimizing the use of materials. Traditional design methods requiring hand-calculations as well as experiments are less desirable because of the rising cost and time. Nowadays, with the development of numerical methods, computer capabilities and computer-aided engineering (CAE) overall, the design process has become much more efficient. This paper presents a procedure to simulate the complex dynamics of a 29-seat bus chassis using finite elements analysis in Ansys software. The results of this simulation are then used to verify the structural integrity of the chassis and support design optimizations.

Abstract: In the present work, the process of interaction of an abrasive particle with the surface of a component is modeled in the framework of dynamic problems of the theory of thermoelasticity, considering plastic deformation, friction and wear of the surface in the contact region. Two boundary contact problems are considered. The first problem deals with the contact interaction of an element of an abrasive particle in the form of a truncated cone and the surface of a part. The circle of smaller diameter of the cone contacts the surface of the part taking into account the friction and plastic deformation of this surface. Kinematic or force boundary conditions are applied to the circle of greater diameter. In the case of kinematic conditions, the normal and tangential displacements of the circle and its rotation are specified. In the case of force conditions, the force and moment are given. In the second task, the hard stamp slides at a constant speed along the flat boundary of the workpiece, the value of the die insertion is set. In the contact area, the sliding friction force is expressed through normal pressure and heating due to the friction and wear. The stress and temperature fields near the contact region are investigated.

Abstract: This paper is focused on multi-scale modeling of solidification and alloy microstructure evolution through computer-aided simulation of the technological processes. Microstructure characterization of cast alloy after centrifugal casting including grain size, dendrite cell size and porosity is of interest in this paper. The centrifugal technological process was simulated using special LVMFlow program for computer-aided analysis of casting technologies to predict shrinkage porosity in axi-symmetric part blanks. The cast blanks were made of Fe-Ni-Co alloy with low thermal expansion and after turning could be used as bearing parts in contact with glass or ceramics. A method of combined simulation of technological processes and operating regimes of cast components was developed. The proposed method of simulating the complicated model allows separating the component from casting geometry in CAE postprocessor and the plot distribution of calculated parameters over the component. Also, this method allows varying diameters of hollow cylindrical casting and choosing the best location of components relative to the predicted porosity in the blank for high quality turning. The distribution of temperature and porosity could be used for more precise calculation of internal stresses in cast component under loading conditions with respect to the structural factors. The structural parameter was stated on a base of the calculated temperature fields to associate grain structure of cast alloy with solidification conditions. The austenitic microstructure of Fe-Ni-Co super-invar alloy was studied on the samples, which were cut from the axi-symmetric part after turning the blank. The calculated structural parameter was assigned with the types of grain structure.

Abstract: At present, use of computer aided engineering (CAE) software is rapidly expanding in the manufacturing industry. However, the CAE software is not an easy tool to use because of its versatility and amount of expertise required to understand and evaluate simulation results. So the operation is more complex, and the error rate is higher in the engineering analysis. A CAE Intelligent Assisted Expert System (IAES) that supports Finite Element analysis was proposed and implemented. The CAE IAS is implemented based on VS2012 development environment, which is based on case and rule based reasoning. It is used to guide and assist CAE engineers to analyze the project, so that the accuracy and efficiency of the analysis are greatly improved and the product performance is better optimized.

Abstract: . Simulation of the FSW process is a complex issue, as it implies interactions between thermal and mechanical phenomena and the quality of the welding depends on many factors. In order to reduce the time of the experimental tests, which can be long and expensive, numerical simulation of the FSW process has been tried during the last ten years. However, there still remain aspects that cannot be completely simulated. In this paper the authors present the steps of the numerical simulation using the finite elements method, in order to evaluate the boundary conditions of the model and the geometry of the tools by using the Arbitrary Lagrangian Eulerian (ALE) adaptive mesh controls.

Abstract: To develop modern CAE systems for durable and reliable structure components design, mathematical modeling of environmentally assisted metal cracking becomes very important. For structure components exploited in aggressive environment and under cyclic load, it is a problem of today. Besides, mathematical rule of damage accumulation of different causes (for instance, hydrogen media impact and cycling) is rarely used in CAE systems, but if such rule was used, crack propagation simulation considering several damage causes would be possible.Environmentally assisted metal cracking model (developed earlier by authors) is described in the paper. This model considers cyclic load and hydrogen embrittlement, the most important characteristics of which are hydrogen environmental concentration and load frequency respectively.The authors’ model successfully predicts effect, known from certain experimental data, that the greater is the frequency, the less hydrogen embrittlement affects fatigue cracks propagation and, vice-versa, that there are certain boundaries of cycling frequency for which embrittlement effect is comparably big.Such boundaries of frequency were numerically estimated by means of the presented model. Plots showing dependency of the component’s life on different defect and loading features are shown.

Abstract: The design of durable structure components requires durability analysis in CAE systems and cloud computations use is favorable for batch processing of multiple same-type calculation routines. To develop CAE durability modules analytical approach to different batch processing systems efficiency estimation is necessary. Such modules are intended for durability analysis of pre-hydrogenated and statically loaded structure components with initial defects. Durability estimate is defined as crack growth time elapsed from initial defect state to structure component fracture. Crack kinetics model had been used to simulate a fracture process, required for safe operation of a structure; crack length curves had been obtained and analyzed. The results were verified with the published experimental data on the subject at hand.The authors’ efficiency criterion was applied for performance analysis of the developed cloud application to find a subset of one modelling parameter in which the application is efficient being constrained in number of computational resources available and in the desirable level of performance.