Comparison stamping and hydro-mechanical forming process for an automobile fuel tank using finite element method

2004 ◽  
Vol 153-154 ◽  
pp. 550-557 ◽  
Author(s):  
J. Kim ◽  
B.M. Son ◽  
B.S. Kang ◽  
S.M. Hwang ◽  
H.J. Park
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Fuel Tank ◽  
Forming Process ◽  
Element Method

Thickness analysis of complex two-step micro-groove on plate during rubber pad forming process

2020 ◽  
pp. 095440622093392
Author(s):  
Fei Teng ◽  
Hongyu Wang ◽  
Juncai Sun ◽  
Xiangwei Kong ◽  
Jie Sun ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Thickness Variation ◽  
Forming Process ◽  
Rubber Pad Forming ◽  
Groove Structure ◽  
Thickness Variations ◽  
Accuracy Of Results ◽  
Plane Slab ◽  
Element Method

The surface groove structure has numerous functions based on their shapes. In order to make these functions developed, both new shapes and processing forms of the surface structures are being innovated. In this paper, not only the advanced rubber pad forming process is used, but also a new kind of micro-groove with two-step structures is designed. A model based on multi-plane slab method is proposed to analyze the process. According to the stress acting condition, a half of two-step micro-groove structure is divided into seven areas in the width direction. The thickness variation of plate in each area is obtained. When the shape, depth, width, and height ratio of the first and second-step micro-groove are different, the thickness variations of the plate are analyzed. In order to verify the accuracy of the model, both finite element method and pressing experiment are done. Based on the results provided by both finite element method and experiment, the accuracy of results calculated by analytical model is verified.

Simulation of Axisymmetric Forming Processes, With Friction, Coupling Finite Elements and Boundary Elements

2006 ◽  
Author(s):  
Dominique Bigot ◽  
Hocine Kebir ◽  
Jean-Marc Roelandt
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Boundary Element Method ◽  
Finite Elements ◽  
Boundary Element ◽  
Symmetric Part ◽  
Forming Process ◽  
Optimal Shapes ◽  
Numerical Software ◽  
Element Method

Nowadays, the simulation of forming processes is rather well integrated in the industrial numerical codes. However, to take into account the possible modifications of the tool during cycle of working, we develop dedicated numerical software. This one more particularly will allow the identification of the fatigue criteria of the tool. With the view to conceiving the optimal shapes of tool allowing increasing their lifespan while ensuring a quality required of the part thus manufactured. This latter uses coupling with friction finite element method — for modelling the axi-symmetric part — and boundary element method — for modelling the tool. For the validation, we modeled forming process.

Research Progress and Application of Multi-Point Forming

2011 ◽  
Vol 221 ◽  
pp. 679-683
Author(s):  
Hui Min Li ◽  
Wei Gang Guo
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Automotive Industry ◽  
Research Progress ◽  
Aviation Industry ◽  
Body Frame ◽  
Forming Process ◽  
Reconfigurable Die ◽  
Element Method

The research progress was introduced about multi-point forming press. It include forming process, reconfigurable die and finite element method. The forming method provided the techonology for development of the aviation industry and automotive industry. The application prospect and techonology dominance were instructed by illuminating body frame of coach.

An Investigation of the Shell Nosing Process by the Finite-Element Method. Part 1: Nosing at Room Temperature (Cold Nosing)

1982 ◽  
Vol 104 (3) ◽  
pp. 305-311 ◽  
Author(s):  
Ming-Ching Tang ◽  
Shiro Kobayashi
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Room Temperature ◽  
Moving Boundary ◽  
Thickness Distribution ◽  
The Finite Element Method ◽  
Forming Process ◽  
Finite Element Program ◽  
Strain Rate Effects ◽  
Element Method

The metal-forming process of shell nosing at room temperature was analyzed by the finite-element method. The strain-rate effects on materials properties were included in the analysis. In cold nosing simulations, the nine-node quadrilateral elements with quadratic velocity distribution were used for the workpiece. The treatment of a moving boundary in the analysis of nosing is discussed and successfully implemented in the finite-element program. FEM simulations of 105-mm dia. shells of AISI 1018 steel and aluminum 2024 were performed and solutions were obtained in terms of load-displacement curves, thickness distribution, elongation, and strain distributions. Comparisons with experimental data show very good agreement.

scholarly journals LOAD PREDICTION ON METAL FORMING PROCESS (FORGING) USING FINITE ELEMENT METHOD.

2020 ◽  
Vol 2 (1) ◽  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Forming ◽  
Weighted Residual Method ◽  
Forming Process ◽  
Residual Method ◽  
Forging Process ◽  
Metal Forming Process ◽  
Metal Blank ◽  
Element Method

Metal forming process is a widely used manufacturing process especially in high volume metal production system. In this paper, the main objective is using Bubnov-Galerkin finite element model to derive the pressure field set up at various cross-sections of a metal blank during a forging process, and the four Lagrange quadratic elements were assembled to represent the various metal blank. The governing equation adopted for this paper is a one-dimensional differential equation describing the pressures exerted on the forging process. During the analysis, the various metal blanks are divided into a finite number of elements and the weighted integral form for each element were formed after applying the Bubnov-Galerkin weighted residual method. A matrix form under certain boundary conditions from the weighted residual method were used to obtain the pressure distribution across the cross-section of the various metal blanks. Finite element results are obtained for a value of a circular disc diameter, thickness, coefficient of friction, principal stress, length, and radius of a circular material. Finite element method and the Exact solution approach are used to achieve and compare both results. Furthermore, the combination of both methods shows that there are potentials for using this approach towards the optimization of metal forming in manufacturing processes and some engineering practices. Keywords: Forging; LaGrange Interpolation Function; Bubnov-Galerkin Weighted Residual Method; Finite Element Method.

scholarly journals A numerical method of optimizing the stretch forming process for the production of panels

2019 ◽  
pp. 386-395
Author(s):  
К.С. Бормотин ◽  
А. Вин
Keyword(s):  
Finite Element Method ◽  
Optimal Control ◽  
Finite Element ◽  
Optimal Control Problem ◽  
Control Problem ◽  
Control Program ◽  
The Finite Element Method ◽  
Forming Process ◽  
Residual Deformations ◽  
Element Method

Рассматривается моделирование технологий обтяжки на прессе для изготовления обшивок двойной кривизны. Автоматизированное формообразование деталей требует разработки управляющей программы и электронной модели пуансона. Качество полученной детали будет зависеть от точности вычисленной и изготовленной формы оснастки, задающей упреждающую форму панели, и траектории деформирования листовой заготовки. При условии заданной оснастки ставится задача оптимального управления для поиска наилучшей траектории движения зажимов в оборудовании. Вводятся критерии оптимизации процессов деформирования, которые обеспечивают минимальную поврежденность и максимальные остаточные деформации. Вычисление критериев выполняется с помощью моделирования и анализа нелинейного деформирования панели с контактными ограничениями методом конечных элементов. Формулируется дискретная задача оптимального управления, которая решается методом динамического программирования. Алгоритмы численного метода, реализованные в пакете программ MSC.Marc, позволяют вычислить оптимальные параметры работы обтяжного пресса. Программная реализация алгоритма выполнена в последовательном и параллельном режимах. На основе вычислительных экспериментов показана эффективность параллельного расчета на кластере вычислительных машин. We analyze the stretchforming technology using a press to manufacture the doublecurvature shells. The automated shaping of parts requires the development of a control program and an electronic model of a punch. The quality of the part obtained depends on the accuracy of the calculated and manufactured tools that specify the anticipated shape of the panel and on the deformation path of the sheet. Under the condition of a given tooling, an optimal control problem is formulated to find the best trajectory of movement of the clamps in the equipment. Some criteria for deformation optimization processes are introduced to ensure a minimum damage and maximum residual deformations. The calculation of the criteria is performed with the aid of modeling and analyzing the panel nonlinear deformation with contact constraints by the finite element method. The problems of inelastic deformation are solved by the finite element method. A discrete optimal control problem is formulated and solved by the methods of dynamic programming. The algorithms are implemented using the MSC.Marc package and allow us to calculate the optimal parameters of the stretchforming press in serial and parallel modes. The obtained numerical results show the efficiency of parallel implementations on a cluster of computers.

scholarly journals Forming Analysis of Bulge Formed Joints Based on Adaptive Finite Element Method

Mechanika ◽  
2021 ◽  
Vol 27 (2) ◽  
pp. 175-181
Author(s):  
Jinjin ZHAI ◽  
Yuantao SUN ◽  
Qing ZHANG ◽  
Xianrong QIN
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Production Efficiency ◽  
Element Model ◽  
Large Error ◽  
Calculation Model ◽  
Adaptive Finite Element Method ◽  
Adaptive Finite Element ◽  
Forming Process ◽  
Element Method

Metal bulk forming is widely used because of its own advantages. In order to improve the production efficiency and reduce the cost, numerical simulation is often used to analyze the volume forming process. Because of the large deformation and non-linearity of the forming process, the finite element method (FEM) has the problem of element distortion, which will affect the accuracy and even lead to the failure of the analysis process. In this paper, an adaptive finite element method (AFEM) is proposed to solve this problem. Firstly, the finite element model is established, and grids are roughly divided. After the analysis, according to the error calculation model, the area with large error is determined by the standard deviation of nominal strain energy of nodes. Then, the grids are refined by dichotomy method, and the calculation is continued, repeating this step until the error meets the requirement. Finally, the numerical analysis of the forging process of the bulge formed joint is taken as an example to prove the accuracy of the proposed method.  

Improvement of Die-Roll Quality in Compound Fine-Blanking Forming Process

2011 ◽  
Vol 337 ◽  
pp. 236-241 ◽  
Author(s):  
Xin Hua Huang ◽  
Hua Xiang ◽  
Xin Cun Zhuang ◽  
Zhen Zhao
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Material Flow ◽  
The Finite Element Method ◽  
Forming Process ◽  
Fine Blanking ◽  
Die Roll ◽  
The Relationship ◽  
Element Method

Nowadays, the compound fine-blanking forming process is one of the most important processes to produce complicate multifunctional parts without subsequent machining. However, the big die-roll occurs in the sharp area is a common problem in this process. In this paper, the method with negative punch-die clearance was proposed to solve this problem by comparing three feasible plans. In addition, the influence on the process with different value of the negative punch-die clearance was studied by the finite element method (FEM). The results of this study verified that the process with suitable value of the negative punch-die clearance can result in significant decrease of the die-roll size. The relationship between the material flow near the region of die-roll and the punch-die clearance was also clarified.

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