Authors: Song Xue, Jie Zhou
Abstract: Precision forging is an important manufacturing procedure of steel synchronizer gear ring
forming. FEM software DEFORM_3D was applied to simulate the forming process and the problems
in the forming process were been solved. The important factors those influence on precision forming
of steel synchronizer gear ring are studied and the results are verified in practice. The results show that
the size of billet, forging temperature, and thickness of web strongly influence the forming quality of
steel synchronizer gear ring.
226
Authors: Dyi Cheng Chen, Ci Syong You, Gua Nying Lai, Syue Cheng Ji
Abstract: In the cross wedge rolling process, many factors must be controlled to obtain the required plastic strain and desired tolerance values. The major factors include the wedge relative velocity, the forming angle, the spreading angle, and sectional reduction. This paper uses rigid-plastic finite element (FE) DEFORMTM 3D software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it is processed for cross wedge rolling. This study analyzes the effective strain, the effective stress, and the X-axial load distribution of the workpiece under various rolling conditions. Furthermore, using simulation software to analyze the changes to the microstructure by the rolling process, this study presents analytical results that confirm the suitability of the current finite element software for cross wedge rolling.
1610
Authors: Lei Cheng, Shui Sheng Xie, You Feng He, Guo Jie Huang, Yao Fu
Abstract: FEM simulation of aluminum profiles in porthole die extrusion process using Lagrange mesh description will inevitably bring mesh self-contact, severe grid distortion and frequent remeshing, which will result in the loss of computational accuracy and excessive calculation time. In order to solve the above mentioned problems, numerical simulation of aluminum profiles with large and complicated cross-section in extrusion process was achieved using finite volume method based on Euler mesh description. The metal flow behavior and welding course was investigated in detail, which can provide the theoretical guide for porthole die design and optimization. In addition, extrusion experiment was carried out by numerical simulation results. The experimental extrudate was in good agreement with the simulation results, which laid a good solid foundation for non-steady state extrusion process analysis of large scale and complicated cross-section profiles.
290
Authors: Liang Chu, Li Jun Shi, Yan Bi, Da Sen Bi
Abstract: In this paper, the nosing process of metal tube with a conical die is investigated using the finite element method, and a series of simulations on the tube nosing process by using the program ABAQUS is carried out. The concrete process of tube nosing deformation is described. Some simulation results on tube nosing deformation such as the distributions of the Von Mises stress and effective strain, the material thickness variation of deformation zone are obtained and analyzed.
1444
Authors: Chin Tarn Kwan, Zhi Kai Chang
Abstract: In this paper, the finite element method is used to investigate the effect of preform shapes on the strain hardening distribution in the wall of the extruded cup of backward extrusion. A series of simulations on the backward extrusion with three different preform shapes (flat, concave and convex) and without preform using the FEM program DEFORM 2D was carried out, respectively. The influence of preform shapes on the effective strain distribution in the extruded wall was examined. A hardness vs. effective strain curve for an annealed AL6061 Aluminum was first obtained using a simple forging test in conjunction with FE simulations, then the curve was used to convert the effective strain distribution into the hardness distribution in the extruded wall. The results of FEM calculations reveal that the concave shape preform has the best effect on the hardness strengthening at the extruded wall of backward extrusion.
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