Research on Cold Orbital Forming of Complex Sheet Metal of Aluminum Alloy

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
Xinghui Han ◽  
Qiu Jin ◽  
Lin Hua
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Mobile Phone ◽  
Sheet Metal ◽  
Experimental Results ◽  
Complex Motion ◽  
Flow Lines ◽  
Inner Surface ◽  
Orbital Forming

This study aims at exploring the potentialities of cold orbital forming in forming complex sheet metal. Aiming at a complex mobile phone shell component of aluminum alloy, two technical schemes for cold orbital forming are first presented. Then, the optimized one, i.e., the more complex inner surface of mobile phone shell is arranged to be formed by the rocking punch with a complex motion, is determined by analyzing the nonuniform plastic deformation laws and punch filling behaviors. On the basis of the optimized technical scheme, the blank geometry in cold orbital forming of mobile phone shell is also optimized based on the forming status of the most difficult forming zone. The consistent finite element (FE) simulated and experimental results indicate that under the optimized technical scheme, not only the bosses in the mobile phone shell are fully formed but also the obtained flow lines are reasonable, which proves that the technical scheme presented in this study is feasible and cold orbital forming exhibits huge potentialities in forming complex sheet metal.

scholarly journals Finite element analysis of deep drawing

2019 ◽  
Vol 11 (9) ◽  
pp. 168781401987456 ◽  
Author(s):  
Dyi-Cheng Chen ◽  
Li Cheng-Yu ◽  
Yu-Yu Lai
Keyword(s):  
Finite Element Analysis ◽  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Deep Drawing ◽  
Drawing Ratio ◽  
Element Analysis ◽  
Forming Mechanism ◽  
Analysis Process ◽  
Plastic Flow Stress

With the advancement of technology, aiming for achieving a greater lightness and smaller size of 3C products, parts processing technology not only needs to explore the basic scientific theory of materials but also needs to discuss the process of deep drawing numerical and the plastic deformation. This study is based on the square shape of the deep drawing numerical simulation, and aluminum alloy plastic flow stress was input into the finite element method for simulation of plastic deformation in the aluminum alloy friction, mold clamping force, and frequency, as well as amplitude in the influence of forming mechanism and the drawing ratio of aluminum alloy. Finite element analysis software has the function of grid automatic rebuild, which can rebuild the broken grid in the analysis into a complete grid shape, which can avoid the divergence caused by numerical calculation in the analysis process. The greater the obtained error value, the best plastic parameters can be found.

Magnetic Assisted Roller Burnishing and Deburring of Flat Metal Surfaces

2012 ◽  
Vol 472-475 ◽  
pp. 908-911 ◽  
Author(s):  
János Kodácsy ◽  
János Liska
Keyword(s):  
Finite Element Method ◽  
Plastic Deformation ◽  
Finite Element ◽  
Strain Hardening ◽  
Metal Surfaces ◽  
Experimental Results ◽  
Surface Finishing ◽  
Software System ◽  
Fem Modelling ◽  
Roller Burnishing

Basically, the Magnetic Assisted (MA) processes of the surface finishing can be divided into two groups: processes based on abrasion and plastic deformation. In this paper the authors present the results of experimental and developing work regarding the Magnetic Assisted Roller Burnishing (MARB) process that operates by plastic deformation and the strain hardening effect. Using Finite Element Method (FEM) modelling software system was prepared to demonstrate the experimental results.

Effects of Porosity on Strength of Aluminum Alloy 2219

2014 ◽  
Vol 984-985 ◽  
pp. 618-626
Author(s):  
G. Jeganlal ◽  
H.M. Umer ◽  
K. Thyagarajan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Experimental Results ◽  
Element Analysis ◽  
Aluminum Alloy 2219

This paper gives the effects of single and multiple pore on the strength of AA2219 welds. Single and double pores are created on welded specimens and tested to study the effects. Also finite element analysis carriedout to correlate the experimental results with theory

A Study on the Aluminum Alloy AA1050 Severely Deformed by Non-Equal Channel Angular Pressing

2013 ◽  
Vol 651 ◽  
pp. 442-447 ◽  
Author(s):  
G.Y. Deng ◽  
C. Lu ◽  
L.H. Su ◽  
J.T. Li ◽  
H.T. Zhu ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Equal Channel Angular Pressing ◽  
Deformation Behavior ◽  
Dead Zone ◽  
Equivalent Plastic Strain ◽  
Exit Channel ◽  
Outer Corner ◽  
Angular Pressing

In order to improve the efficiency of grain refinement, a study on the modified process (called Non-equal channel angular pressing) from the conventional equal channel angular pressing has been conducted. The deformation behavior of aluminum alloy AA1050 deformed by the Non-equal channel angular pressing which has a smaller width in the exit channel than the entry channel was examined based on the finite element simulations. The results revealed that a smaller ratio of dE and dI (dE/dI) leads to a larger equivalent plastic strain. It is not only beneficial to enhance the plastic deformation but also very helpful to get rid of the development of dead zone in the outer corner of die by decreasing the exit channel width by comparing with the conventional process.

Comparing Methods for Establishing Multiscale Material Properties of 0.2 mm Thick Annealed ASTM 304

2015 ◽  
Author(s):  
William J. Emblom ◽  
Md. F. S. Ibne Islam ◽  
Richard J. Jones ◽  
Mitra Aithal ◽  
Scott Wagner ◽  
...  
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Material Properties ◽  
Strain Measurement ◽  
Measurement Errors ◽  
Element Model ◽  
Experimental Results ◽  
304 Stainless Steel ◽  
Membrane Theory ◽  
Forming Process

Producing fuel cells bipolar plates and other devices such as microscale heat exchangers for electronics requires both macroscale and microscale forming processes. At the macroscale, typically, mechanical properties of sheet metal are determined by performing tensile tests. In addition, it has long been recognized that bi-axial tension tests, dome tests, and hydroforming or viscous bulge tests provide the basis for improved understanding of the mechanics of sheet metal forming. At the microscale strain gauges are too large for measuring strains in small regions and membrane theory is only valid at the poles of the bulge. Continuum mechanics models are useful but require tedious thickness measurements for multiple work pieces, requiring extensive sample preparation and analysis. In this paper experimental results from hydroforming tests for 0.2-mm thick annealed ASTM 304 stainless steel sheet in 11 mm, 5 mm, and 1 mm diameter open dies at various pressures were evaluated. The height of the bulge at the pole and strains based upon measurements of 127 micron strain grids were determined. These dies represent the transition from a small macroscale process to a microscale forming process. Two methods were used to estimate material properties: an analytical model and an iterative method which compared experimental strain results with the strains from a finite element model where the Holloman constitutive properties of the sheet were varied. The problems estimating material properties based upon grid strain measurement, membrane theory, and the iterative finite element approaches were investigated and the results were compared. This study indicates that membrane theory will provide adequate predictions for Holloman constructive properties provided the assumptions for membrane theory are not violated. However, using measured microscale grid deformation strains does not produce very good agreement estimates of the Holloman constitutive model when comparing experimental results with FEA strains. It is believed that while the grid strain measurement method used results in strain measurement errors of less than 1.5% of strain, this error is sufficient to result in enough uncertainty to produce results that are inconsistent with other methods.

scholarly journals Analytical and Numerical Model of Aluminum Alloy Swaging Ring Design to Study the Effect on the Sealing for Piping Systems

2021 ◽  
Vol 7 (1) ◽  
pp. 107-117
Author(s):  
Ahmet Atak
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Design Parameters ◽  
Modeling Methods ◽  
Analysis Methodology ◽  
Hand Tool ◽  
Cryogenic Vacuum ◽  
Piping Systems ◽  
The Impact

In various fields of engineering, the assembly and repair of hydraulic installations are accomplished by joining the pipes. In such applications, the ring swaging method is used to connect the fittings to the pipes by means of a hydraulic hand tool. The basis to develop a swaging tool relies on the knowledge of the design parameter that influence plastic deformation of the swaging ring. In addition to build control over the design parameters, it is necessary to join pipes under severe conditions such as cryogenic vacuum and constrained space which require an intact sealing. In this study, the effect of swaging ring designs on sealing and strength has been examined and different swaging methods have been investigated by finite element modeling methods. Based on the obtained results, the analysis methodology of ring swaging and the characteristic impact of swaging ring design on the sealing of pipe connection are shown. The prime novelty of the study is to report the impact of swaging ring design and geometry on sealing efficiency of the pipe connection. The results of the study open new avenues for the development of efficient tools for designing swaging rings. Doi: 10.28991/cej-2021-03091641 Full Text: PDF

An experimental validation of volume conservation assumption for aluminum alloy sheet metal using digital image correlation method

2016 ◽  
Vol 52 (1) ◽  
pp. 24-29 ◽  
Author(s):  
Xin Xie ◽  
Junrui Li ◽  
Bernard Sia ◽  
Tian Bai ◽  
Thorsten Siebert ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Digital Image Correlation ◽  
Sheet Metal ◽  
Volume Change ◽  
Digital Image ◽  
Experimental Validation ◽  
Tensile Tests ◽  
Experimental Results ◽  
Image Correlation ◽  
Volume Conservation

This article shows an experimental validation of the volume conservation assumption (zero plastic volume change assumption) for aluminum alloy (AA6000) sheet metal. A series of tensile tests were conducted. During the tensile tests, an optimized digital image correlation setup was used to simultaneously measure three principal strain components. The experimental results show that, at locations outside the necking band, AA6000 strictly follows the zero plastic volume change assumption throughout the duration of the test. Inside the necking band, AA6000 follows the zero plastic volume change assumption in the elastic range and early plastic range. However, before failure, a visible volume strain increase can be found inside the necking band, which shows that, in the deep plastic zone, AA6000 does not always follow the volume conservation assumption. The experiment plan, measurement setup optimization, experimental results and data analysis are shown in detail.

Study of Forging Forming of 7075 Aluminum Alloy Bicycle Pedal

2012 ◽  
Vol 579 ◽  
pp. 101-108 ◽  
Author(s):  
Dyi Cheng Chen ◽  
Fung Ling Nian ◽  
Jiun Ru Shiu ◽  
Wen Hsuan Ku
Keyword(s):  
Plastic Deformation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Effective Strain ◽  
High Strength ◽  
Mold Temperature ◽  
Grain Structure ◽  
7075 Aluminum Alloy ◽  
Rigid Plastic ◽  
Plastic Deformation Behavior

Forging is simple and inexpensive in mass production. Metallic materials are processed through plastic deformation. This not only changes the appearance but also changes the internal organization of materials that improve mechanical properties. However, regarding manufacturing of plastic products, many processing factors must be controlled to obtain the required plastic strain and desired tolerance values. In this paper, we employed rigid-plastic finite element (FE) DEFORMTM software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it used to forge bicycle pedals. First we use Solid works 2010 3D graphics software to design the bicycle pedal of the mold and appearance, moreover import finite element (FE) DEFORMTM 3D software for analysis. The paper used rigid-plastic model analytical methods, and assuming mode to be rigid body. A series of simulation analyses in which the variables depend on different temperatures of the forging billet, round radius size of ram, punch speed, and mold temperature were revealed to confirm the predicted aluminum grain structure, effective stress, effective strain, and die radial load distribution for forging a bicycle pedal. The analysis results can provide references for forming bicycle pedal molds. Finally, this study identified the finite element results for high-strength design suitability of a 7075 aluminum alloy bicycle pedal.

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