Papers by Keyword: Ovality

Abstract: In this paper, the problem distortion the end of a cylindrical workpiece in the cutting process on hot shears before being fed to the piercing mill is considered. To solve this problem, a new calibration of knives has been developed, and a finite element model hot cutting shears has been developed using the DEFORM-3D computer simulation software package. Modeling the cutting process using the proposed calibration has been carried out. It was found that the knife calibers geometry plays an important role in the formation end part geometry of the blank. Based on the simulation results, it was concluded that proposed calibration reduces the ovality workpiece end by almost 2 times in comparison with current calibration. Recommendations have been developed for the production of changes in the existing technology for cutting pipe billets.

Abstract: Modeling of the cold flow forming process for manufacturing of tube shaped solution annealed H30 Aluminum alloy has been considered in this present study. Three inputs (feed-speed ratio, roller in-feed and roller axial stagger) and three outputs viz. spring back, ovality and internal diameter have been considered for the present study.. Adaptive network-based fuzzy inference system (ANFIS) in Matlab platform has used for modeling purposes and its performance is compared with regression model. ANFIS has completely outperformed the regression models. Percentage accuracy in predicting all the three responses are found to be very high with ANFIS models. Prediction of ovality against the test data using regression analysis is found to be extremely erroneous. It indicates that additional process parameters are involved in predicting ovality which are not captured during the experimentation.

Abstract: Nitride coatings were deposited by vacuum arc plasma, in an atmosphere of argon and nitrogen using different deposition conditions of part location and configuration, angle between plasma flow and processing surface. The coating thickness, part dimensions and surface roughness were measured before and after coating deposition. The type of part poor shape precision after coating deposition by vacuum arc plasma was defined. An impact of coating deposition by vacuum arc discharge on the part dimensional and form accuracy was revealed. The effect of parts location on dimensional and radial surfaces form accuracy was induced. The effect of coating surface polythickness on part dimensional and form accuracy for parts with different stiffness was defined. The impact of part location area and parts quantity on coating thickness, surface roughness, dimensional and form accuracy of part was revealed. The coating thickness distribution law, parts quality class and accuracy degree after vacuum ion plasma coating deposition were assigned.

Abstract: In drilling and boring process, the relief in clamping stress causes deformations that cause variations in the geometry of the drilled hole. In automobile industry, when such holes are used to hold gear systems or rods in place, this variation in geometry leads to poor fitting and subsequent failure. To avoid this, high level accuracy is required which is both expensive and time-consuming. Therefore, a high percentage of such drilled parts are rejected in industry. The present paper addresses this problem by characterizing the variations in hole geometry as a function of clamping force, hole diameter, hole eccentricity (distance of hole-center from center of drilled face) and angular position of hole with respect to clamp location. The analysis result quantifies the comparative effect of each aforementioned factor on hole geometry variation. Taguchi Method based Design of Experiments using L25 orthogonal array has been used for performing the parametric design to arrive at the best settings of the 4 parameters. The optimal settings minimize ovality and displacement of the hole-center, and thus increase hole-fitting and its reliability against manufacturing variability.

Abstract: Around 70% of the cost in piping industry is spent in the pipe manufacturing with optimum design of pipes without defects. Research on design of pipes has gained importance from the last decade. There are numerous methods being developed to improve the efficiency of piping units considering various parameters. The pipe tends to flatten when they are forced to bend, this geometrical changes has a significant role in the acceptability criteria of pipes. It is necessary to bend pipes in order to transmit liquid or gas from one place to other place. In this work special attention is given to pipe bends because of high stress concentration due to various loading conditions. From several kinds of piping systems, process piping systems are chosen for analysis since pipes used here transport important and hazardous materials. Damage to such piping system can cause serious loss to economy and human lives. The geometrical imperfection associated with bending of pipes is ovality. This degree of ovality determines the acceptance of pipes. Thickening and thinning effects cause additional problems like large plastic deformation and loss of flexibility respectively. Hence estimation of the best degree of ovality is required. In this work effect of ovality is estimated by taking the internal fluid pressure and In plane bending moment into account.

Abstract: Fluctuations in material properties of the incoming steel for UOE forming process are widespread. According to the statistics, the fluctuation range of the yield strength of the same grade pipeline steel is around 80MPa. Robust optimization methods have been widely applied in sheet metal forming area. In this paper, experiments were conducted to investigate how a stochastic material behavior of noise factors affected UOE forming quality. Robust design models integrated with response surface method for UOE forming process were established to minimize impact of the variations and improve the qualified rate of UOE pipe ovality. Support vector machine in both classification and regression was adopted to map the relation between input process parameters and forming qualities. The deterministic and robust optimization results are presented and compared, demonstrating increased process robustness and decreased number of product rejects by application of the robust optimization approach.

Abstract: A two-dimensional finite element simulation model of longitudinal welded pipe is established by the nonlinear finite element software ABAQUS. Testing enlargement mould is used for the expanding experiments for the welded pipe under the laboratory condition. The expanding force, ovality and the shape are simulated and measured. Comparing the experimental and the simulated results, the values are fitted well.

Abstract: This paper quantifies the effect of ovality and thinning/thickening of thin-wall pipe bend modeled using the geometric parameters of r/t=15 and 20 and λ=0.1 to 0.3. For each model the ovality and thinning is varied from 5% to 20 % in steps of 5 % .The collapse loads were obtained from twice-elastic-slope method of pipe bends subjected to out-of-plane moment with and without internal pressure. Large displacement analysis was performed on elastic-perfectly plastic material using the nonlinear FE package of ABAQUS. The analyzed shows that the thinning effect is insignificant and ovality produce the significant effect of upto 27.7% decrease in collapse load for pipe bend subjected to combined moment and internal pressure.

Abstract: The presence of thorough wall circumferential cracks has a detrimental effect on collapse load of elbows. The existing theoretical solutions do not correctly quantify the weakening effect due to the presence of the circumferential through wall crack in shape imperfect pipe bends. The present study has been done to investigate the effect of ovality and thinning on the collapse moment of 90° elbow with critical throughwall circumferential crack under in-plane bending moment using elastic-plastic finite element analysis considering large geometry change.

Abstract: The article deals with the creation of models for the analysis of plastic zones generation in ductile cast iron. The aim is the study of the microplasticization process near the graphite particles border. In creating the graphite particle model there is randomly chosen shape and orientation of the particle. The basic characteristic of the shape is ovality (the ratio of the inscribed circle to the circumscribed circle). The size of plastic deformation and the size of the plastic area are monitored by the microplasticization process analysis. The results are statistically elaborated to determine the relationship between graphite particle ovality and microplasticization caused by an inclusion.