Experimental and Numerical Investigation on Filling Roll Bending of Aluminum Alloy Integral Panel

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Han Xiao ◽  
Shi-hong Zhang ◽  
Jin-song Liu ◽  
Ming Cheng ◽  
Hong-xi Liu
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Numerical Methods ◽  
Process Parameters ◽  
Element Model ◽  
Geometric Accuracy ◽  
Roll Bending ◽  
Bending Process ◽  
Simulation Results ◽  
Deformation Homogeneity

Integral panels are widely used in aerospace industries. A filling roll bending process is proposed to form integral panels. Filling roll bending experiments of aluminum alloy integral panels were carried out. A 3D elastic–plastic finite element model of filling roll bending process was established and validated by experiment. The effects of filler and process parameters on the deformation homogeneity of the panels were analyzed by using experimental and numerical methods. The results indicate that the filler can improve the deformation homogeneity. With the increasing of the displacement of the top-roller from 5 mm to 40 mm, the experimental and simulation bending radii with filler all reduce, the experimental results reduce from 5806 mm to 190 mm, the simulation results reduce from 5924 mm to 199 mm, and the simulation springback rates with filler reduce from 0.92% to 0.15%. It is proved that high geometric accuracy of the integral panels can be obtained by using filling roll bending process.

scholarly journals Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Metals ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 31 ◽  
Author(s):  
Anheng Wang ◽  
Hongqian Xue ◽  
Emin Bayraktar ◽  
Yanli Yang ◽  
Shah Saud ◽  
...  
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Element Model ◽  
Effective Control ◽  
Curvature Radius ◽  
3D Fem ◽  
Fe Method ◽  
Element Analysis ◽  
Roll Bending ◽  
Bending Process

This paper focuses on the twist defects and the control strategy in the process of four-roll bending for aluminum alloy Z-section profiles with large cross-section. A 3D finite element model (3D-FEM) of roll bending process has been developed, on the premise of the curvature radius of the profile, the particularly pronounced twist defects characteristic of 7075-O aluminum alloy Z-section profiles were studied by FE method. The simulation results showed that the effective control of the twist defects of the profile could be realized by adjusting the side roller so that the exit guide roll was higher than the entrance one (the side rolls presented an asymmetric loading mode with respect to the main rolls) and increasing the radius of upper roll. Corresponding experimental tests were carried out to verify the accuracy of the numerical analysis. The experimental results indicated that control strategies based on finite element analysis (FEA) had a significant inhibitory function on twist defects in the actual roll bending process.

Numerical Simulation on Spiral Hot Bending Process for End Sheet of Tubular Pile

2012 ◽  
Vol 562-564 ◽  
pp. 1373-1376
Author(s):  
Shi Min Xu ◽  
Hua Gui Huang ◽  
Deng Yue Sun
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Radial Direction ◽  
Three Dimensional ◽  
Element Model ◽  
Manufacturing Method ◽  
Forming Technology ◽  
Bending Process ◽  
Simulation Results ◽  
The Moment

A new manufacturing method of spiral hot bending process for the end sheet of tubular pile was introduced in this paper. A three-dimensional (3-D) thermal-mechanical coupled elastic-plasticity finite element model was setup to simulate the hot bending process, and then, the section deformation mechanism from hot bar by rolling to the end sheet has been investigated from the simulation results. The industry manufacture conditions show that the efficiency and quality has been highly improved by the spiral hot bending process. The thickness variety along the radial direction of the workpiece has also been analyzed, the moment and force during the hot bending was also presented in this paper. These conclusions obtained can guide for the forming technology making for both the end sheet of tubular pile and other ring parts.

Effect of Temperature on Geometric Accuracy of AZ31 Profile during Warm Pre-Tension Rotation Bending

2011 ◽  
Vol 299-300 ◽  
pp. 432-435
Author(s):  
Han Xiao ◽  
Shi Hong Zhang ◽  
Jin Song Liu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cross Section ◽  
Element Model ◽  
Effect Of Temperature ◽  
Geometric Accuracy ◽  
Elastic Plastic ◽  
Bending Process ◽  
Forming Temperature ◽  
The Cross

A warm pre-tension rotation bending process is presented to bend the AZ31 profile. A 3D elastic-plastic thermo-mechanical coupled finite element model is established to investigate the effect of forming temperature on the geometric accuracy of the profile. The results indicate that with increasing forming temperature, the springback angles decrease from 8.37° to 7.2°; the bending radii decrease from 90.69 mm to 89.67 mm; the cross-section distortion of the bent profile increases.

scholarly journals Finite Element Analysis of Forward Slip in Micro Flexible Rolling of Thin Aluminium Strips

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1062 ◽  
Author(s):  
Feijun Qu ◽  
Jianzhong Xu ◽  
Zhengyi Jiang
Keyword(s):  
Grain Size ◽  
Finite Element ◽  
Finite Element Model ◽  
Process Parameters ◽  
Element Model ◽  
Rolled Strip ◽  
Forward Slip ◽  
Flexible Rolling ◽  
Multilinear Regression Analysis ◽  
Simulation Results

This study delineates a novel finite element model to consider a pattern of process parameters affecting the forward slip in micro flexible rolling, which focuses on the thickness transition area of the rolled strip with thickness in the micrometre range. According to the strip marking method, the forward slip is obtained by comparison between the distance of the bumped ridges on the roll and that of the markings indented by the ridges, which not only simplifies the calculation process, but also maintains the accuracy as compared with theoretical estimates. The simulation results identify the qualitative and quantitative variations of forward slip with regard to the variations in the reduction, rolling speed, estimated friction coefficient and the ratio of strip thickness to grain size, respectively, which also locate the cases wherein the relative sliding happens between the strip and the roll. The developed grain-based finite element model featuring 3D Voronoi tessellations allows for the investigation of the scatter effect of forward slip, which gets strengthened by the enhanced effect of every single grain attributed to the dispersion of fewer grains in a thinner strip with respect to constant grain size. The multilinear regression analysis is performed to establish a statistical model based upon the simulation results, which has been proven to be accurate in quantitatively describing the relationship between the forward slip and the aforementioned process parameters by considering both correlation and error analyses. The magnitudes of each process parameter affecting forward slip are also determined by variance analysis.

Numerical Simulation of Bending Angle on Geometric Accuracy of AZ31 Mg Alloy Profile during Warm Bending Process

2012 ◽  
Vol 482-484 ◽  
pp. 314-317
Author(s):  
Han Xiao ◽  
Yu Chun Dang ◽  
Shi Hong Zhang ◽  
De Hong Lu
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Finite Element Model ◽  
Cross Section ◽  
Element Model ◽  
Mg Alloy ◽  
Geometric Accuracy ◽  
Bending Angle ◽  
Az31 Mg Alloy ◽  
Bending Process

A 3D elastic-plastic thermo-mechanical coupled finite element model of AZ31 Mg alloy profile during warm bending process was established. The effect of bending angle on the geometric accuracy of the profile was investigated. The results indicate that with increasing bending angle, the springback angles increase from 7.56° to 8.27°; the bending radii decrease from 90.15 mm to 90.01 mm; the cross-section distortion of the bent profile increases.

scholarly journals Investigation of the Thickness Differential on the Formability of Aluminum Tailor Welded Blanks

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 875
Author(s):  
Jie Wu ◽  
Yuri Hovanski ◽  
Michael Miles
Keyword(s):  
Experimental Data ◽  
Finite Element ◽  
Numerical Model ◽  
Plastic Strain ◽  
Finite Element Model ◽  
Equivalent Plastic Strain ◽  
Element Model ◽  
Dome Height ◽  
Tailor Welded Blanks ◽  
Simulation Results

A finite element model is proposed to investigate the effect of thickness differential on Limiting Dome Height (LDH) testing of aluminum tailor-welded blanks. The numerical model is validated via comparison of the equivalent plastic strain and displacement distribution between the simulation results and the experimental data. The normalized equivalent plastic strain and normalized LDH values are proposed as a means of quantifying the influence of thickness differential for a variety of different ratios. Increasing thickness differential was found to decrease the normalized equivalent plastic strain and normalized LDH values, this providing an evaluation of blank formability.

scholarly journals Reconstruction finite element model of cars

2021 ◽  
Vol 4 (1) ◽  
pp. first
Author(s):  
Lý Hùng Anh ◽  
Nguyễn Phụ Thượng Lưu ◽  
Nguyễn Thiên Phú ◽  
Trần Đình Nhật
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Finite Element Models ◽  
Crash Analysis ◽  
Inertia Moment ◽  
Frontal Crash ◽  
Analysis Center ◽  
Simulation Results ◽  
And Behavior

The experimental method used in a frontal crash of cars costs much time and expense. Therefore, numerical simulation in crashworthiness is widely applied in the world. The completed car models contain a lot of parts which provided complicated structure, especially the rear of car models do not contribute to behavior of frontal crash which usually evaluates injuries of pedestrian or motorcyclist. In order to save time and resources, a simplification of the car models for research simulations is essential with the goal of reducing approximately 50% of car model elements and nodes. This study aims to construct the finite element models of front structures of vehicle based on the original finite element models. Those new car models must be maintained important values such as mass and center of gravity position. By using condition boundaries, inertia moment is kept unchanged on new model. The original car models, which are provided by the National Crash Analysis Center (NCAC), validated by using results from experimental crash tests. The modified (simplistic) vehicle FE models are validated by comparing simulation results with experimental data and simulation results of the original vehicle finite element models. LS-Dyna software provides convenient tools and very strong to modify finite element model. There are six car models reconstructed in this research, including 1 Pick-up, 2 SUV and 3 Sedan. Because car models were not the main object to evaluate in a crash, energy and behavior of frontal part have the most important role. As a result, six simplified car models gave reasonable outcomes and reduced significantly the number of nodes and elements. Therefore, the simulation time is also reduced a lot. Simplified car models can be applied to the upcoming frontal simulations.

Numerical and Experimental Analysis of Self Piercing Riveting Process with Carbon Fiber-Reinforced Plastic and Aluminium Sheets

2013 ◽  
Vol 554-557 ◽  
pp. 1045-1054 ◽  
Author(s):  
Welf Guntram Drossel ◽  
Reinhard Mauermann ◽  
Raik Grützner ◽  
Danilo Mattheß
Keyword(s):  
Finite Element ◽  
Carbon Fiber ◽  
Finite Element Model ◽  
Simulation Model ◽  
Process Parameters ◽  
Process Model ◽  
Element Model ◽  
Model Parameters ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced

In this study a numerical simulation model was designed for representing the joining process of carbon fiber-reinforced plastics (CFRP) and aluminum alloy with semi-tubular self-piercing rivet. The first step towards this goal is to analyze the piercing process of CFRP numerical and experimental. Thereby the essential process parameters, tool geometries and material characteristics are determined and in finite element model represented. Subsequently the finite element model will be verified and calibrated by experimental studies. The next step is the integration of the calibrated model parameters from the piercing process in the extensive simulation model of self-piercing rivet process. The comparison between the measured and computed values, e.g. process parameters and the geometrical connection characteristics, shows the reached quality of the process model. The presented method provides an experimental reliable characterization of the damage of the composite material and an evaluation of the connection performances, regarding the anisotropic property of CFRP.

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