Papers by Keyword: Finite Element (FE) Simulation

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Authors: Zhi Qiang Zhang, Dong Sheng Qian, Lin Hua
Abstract: Ring parts of duplicate gear, double-side flange, high pressure value body, are widely used in engineering machinery, have the common geometrical characteristic of thick-wall, small-hole and deep-groove on the surface. High energy consumption, low material utilization, low productivity and poor quality exist in the current forging technology of this type of rings. In this paper, a new forming method for this type of rings named combined ring rolling (CRR) is proposed. The forming principle of CRR is introduced at first, then, a 3-D coupled thermo-mechanical FE model for the CRR process of a double-side flange ring is developed. By simulation and analysis, the feasibility of CRR technology is testified, and the evolution and distribution rules of stain, temperature, force and power in the rolling process are revealed. The results provide the guideline for the research and development of CRR technology.
Authors: Jun Ming Wang, Fu Yuan Tong, Xiao Xue Li
Abstract: By simplifying the geometric shape of abrasive grain in a cone-shape, the authors conduct the 3D dynamic finite element simulation on profile grinding with axial feed by single abrasive grain using deform-3D software. Analysis is made on the influence upon the grinding forces in case of the same grinding speed, the same grinding depth and the same friction factor between wheel and workpiece at different axial feed. The results show that the normal force and the tangential force increase with the increase of axial feed, but the axial force decreases with the axial feed.
Authors: Xiu Mei Zhou, Lin Hua, Dong Sheng Qian
Abstract: Special rolling is also called rotary forming process, which is an advanced manufacture technology of making workpiece generate deformation in a rotary state by continuous local plastic forming. Disk rotary parts with outer stepped cross-section, such as wheels, flanges, valves and so on, are widely used in engineering machinery. Traditionally, this kind of part is manufactured by forging and cutting, which consumes a lot of energy and materials especially to the large size part. In this paper, a new specific rolling technique called three rolls cross rolling is first presented to produce this kind of part, and the principle and characteristics of this technique are described in detail. Then, base on the principle of the three rolls cross rolling, a 3D coupled thermo-mechanical FE model is developed under ABAQUS software environment. As a result, under the simulation and analyses of a real example, the feasibility of this technique is verified, and the evolutional laws of the strain, temperature and rolling force and power parameters during the process are investigated as well. The obtained results provide valuable guidelines for the further investigation on the forming characteristic of the three rolls cross rolling technique.
Authors: Fritz Klocke, Dieter Lung, Christoph Essig
Abstract: The aim of the presented work was to define a criterion for the prediction of chip breakage in turning C45E+N (AISI 1045). The chip formation, the chip flow and the expansion of the chip due to collision with the periphery were modelled three-dimensionally using the Finite Element Method (FEM). The mechanical loads in the chip breakage zone were determined by comparing the modelled chip with high speed filming records of the real chip breakage cycle. Based on the calculated loads in the chip breakage zone a novel damage criterion based on an approach of Johnson and Cook was developed. This criterion enables the FEM-model to simulate chip breakage three-dimensionally for different tool geometries and varying cutting parameters. The enhanced FE model correlated well with high speed filming records of the chip flow and breakage as well as with the empirical determined cutting forces and chip temperatures.
Authors: W.H. Liu, Xin Ming Zhang, Jian Guo Tang, Yu Xuan Du
Abstract: Void growth in aluminum single crystals is simulated using the finite element method, to illustrate the effect of grain orientation on void growth, a rate dependent crystal plasticity constitutive theory is implemented as a user-defined plasticity subroutine. A three-dimension unit cell including a sphere void was employed using three-dimensional 12 active slip systems. The computed results for several grain orientations are compared, which have shown that crystallographic orientation has significant influence on growth behavior of void. And the void growth direction and shape significantly depend on the crystallographic orientation. Due to plastic flow localization and anisotropic behavior, void which has an initial sphere shape, develops an irregular shape and some corners.
Authors: M. Loh-Mousavi, Kenichiro Mori, K. Hayashi, Seijiro Maki, M. Bakhshi
Abstract: The effect of oscillation of internal pressure on the formability and shape accuracy of the products in a pulsating hydroforming process of T-shaped parts was examined by finite element simulation. The local thinning was prevented by oscillating the internal pressure. The filling ratio of the die cavity and the symmetrical degree of the filling was increased by the oscillation of pressure. The calculated deforming shape and the wall thickness are in good agreement with the experimental ones. It was found that pulsating hydroforming is useful in improving the formability and shape accuracy in the T-shape hydroforming operation.
Authors: M. Siddique, Muhammad Abid, H.F. Junejo, R.A. Mufti
Abstract: This paper presents results of detailed three-dimensional finite element simulation of residual stress distribution in welded Pipe-Flange Joints with emphasis on the effect of welding parameters and geometrical size of the model. Single-pass Metal Inert Gas welding with single “V” Butt-weld geometry is used in the study. The effect of two basic welding parameters including welding current and speed and two geometrical parameters i.e. pipe diameter and wall-thickness are examined. For both welding current and welding speed, three sets of parameters comprising of low, medium and high values are used. To analyze the effect of each parameter explicitly only one parameter is changed at one time. In most of the cases 100 mm nominal pipe diameter is used. A FE Model for 200 mm nominal pipe diameter is also analyzed to determine the effect of pipe diameter.
Authors: Hisaki Watari, Hidemitsu Hamano, Shi Ichi Nishida, Hayato Asou
Abstract: In recent several years, although production of magnesium has risen dramatically, production of magnesium alloy sheet remains still at a very low level in practical use. The major barrier to greatly increased magnesium alloy use has been in still primarily high manufacturing cost as well as poor work ability of wrought magnesium sheet alloys. One of the author has investigated in cold roll forming of magnesium alloy, however detailed forming characteristics of the wrought magnesium alloy sheets has not been clarified. The aim of the study is to confirm possibilities of practical use of wrought magnesium alloy by using told roll forming process. A three dimensional elasto-plastic analysis by finite element method (FEM) has been conducted to examine the shapes of cross section, spring back characteristics, bending strains and longitudinal membrane strain of magnesium alloy sheet and cold rolled steel sheet during forming.
Authors: Luo Xing Li, Jia Zhou, X. He, Jie Zhou, Jurek Duczczyk
Abstract: The present case study addressed a practical problem of wall thickness attenuation during extrusion to produce a complex thin-walled hollow magnesium profile. A HyperWorks FEM software package was employed to aid in identifying the causes for the wall thickness attenuation. Recommendations were made to adjust the interspacing between the mandrels and the height of the welding chamber. The modified dies yielded much improved results in terms of velocity and hydrostatic pressure uniformity. The wall thickness of the extrudate predicted using FEM simulation was very close to experimental measurements. The case study demonstrated the feasibility of using FEM simulation as a useful tool to solve industrial problems encountered in the production of complex profiles.
Authors: Ramazan Kayikci, M. Durat, E. Nart, I. Ozsert
Abstract: In this study, using materials thermo-physical data and CAD/CAE techniques the thermal fatigue life of a permanent mould is estimated. 3D solid models of the mould-casting system consisted of a permanent mould made from grade 60 ductile iron and an aluminium 7% Si, 0.3 % Mg Casting alloy (A356) were constructed in a CAD system. After defining all boundary and initials conditions in a finite element environment a thermal solution of the permanent mould casting is achieved repeatedly for every cycle until the steady-state temperature change is reached. The elastic-plastic stress calculation is performed by using the thermal history obtained from the thermal analysis. At the end, the residual stresses are determined and used for the thermal fatigue life estimation. The results showed that using the proposed CAD/CAE techniques the fatigue life of a permanent mould can be estimated.
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