A Virtual Model for Aluminum Hot Forging Using an Artificial Neural Network Material Model Within Finite Element Analysis

2005 ◽  
Author(s):  
B. Scott Kessler ◽  
A. Sherif El-Gizawy
Keyword(s):  
Finite Element ◽  
Effective Means ◽  
Hot Forging ◽  
Material Model ◽  
Element Model ◽  
Operating Conditions ◽  
Element Analysis ◽  
Preliminary Model ◽  
Wide Range ◽  
Artificial Neural

The accuracy of a finite element model for design and analysis of a metal forging operation is limited by the incorporated material model’s ability to predict deformation behavior over a wide range of operating conditions. Current rheological models prove deficient in several respects due to the difficulty in establishing complicated relations between many parameters. More recently, artificial neural networks (ANN) have been suggested as an effective means to overcome these difficulties. In the present work, a previously developed ANN with the ability to determine flow stresses based on strain, strain rate, and temperature is incorporated with finite element code. Utilizing this linked approach, a preliminary model for forging an aluminum wheel is developed. This novel method, along with a conventional approach, is then measured against the forging process as it is currently performed in actual production.

Incorporating Neural Network Material Models Within Finite Element Analysis for Rheological Behavior Prediction

2006 ◽  
Vol 129 (1) ◽  
pp. 58-65 ◽  
Author(s):  
B. Scott Kessler ◽  
A. Sherif El-Gizawy ◽  
Douglas E. Smith
Keyword(s):  
Finite Element ◽  
Effective Means ◽  
Element Model ◽  
Operating Conditions ◽  
Behavior Prediction ◽  
Element Analysis ◽  
Material Models ◽  
Rheological Models ◽  
Wide Range ◽  
Novel Method

The accuracy of a finite element model for design and analysis of a metal forging operation is limited by the incorporated material model’s ability to predict deformation behavior over a wide range of operating conditions. Current rheological models prove deficient in several respects due to the difficulty in establishing complicated relations between many parameters. More recently, artificial neural networks (ANN) have been suggested as an effective means to overcome these difficulties. To this end, a robust ANN with the ability to determine flow stresses based on strain, strain rate, and temperature is developed and linked with finite element code. Comparisons of this novel method with conventional means are carried out to demonstrate the advantages of this approach.

Incorporating Neural Network Material Models Within Finite Element Analysis for Rheological Behavior Prediction

2005 ◽  
Author(s):  
B. Scott Kessler ◽  
A. Sherif El-Gizawy ◽  
Douglas E. Smith
Keyword(s):  
Finite Element ◽  
Effective Means ◽  
Element Model ◽  
Operating Conditions ◽  
Behavior Prediction ◽  
Element Analysis ◽  
Material Models ◽  
Rheological Models ◽  
Wide Range ◽  
Novel Method

The accuracy of a finite element model for design and analysis of a metal forging operation is limited by the incorporated material model’s ability to predict deformation behavior over a wide range of operating conditions. Current rheological models prove deficient in several respects due to the difficulty in establishing complicated relations between many parameters. More recently, artificial neural networks (ANN) have been suggested as an effective means to overcome these difficulties. To this end, a robust ANN with the ability to determine flow stresses based on strain, strain rate, and temperature is developed and linked with finite element code. Comparisons of this novel method with conventional means are carried out to demonstrate the advantages of this approach.

Pipeline Dent Management Program

2002 ◽  
Author(s):  
Scott D. Ironside ◽  
L. Blair Carroll
Keyword(s):  
Finite Element ◽  
Oil And Gas ◽  
Selection Process ◽  
Element Model ◽  
Field Trials ◽  
Management Program ◽  
Operating Conditions ◽  
Published Data ◽  
Element Analysis ◽  
The Past

Enbridge Pipelines Inc. operates the world’s longest and most complex liquids pipeline network. As part of Enbridge’s Integrity Management Program In-Line Inspections have been and will continue to be conducted on more than 15,000 km of pipeline. The Inspection Programs have included using the most technologically advanced geometry tools in the world to detect geometrical discontinuities such as ovality, dents, and buckles. During the past number of years, Enbridge Pipelines Inc. has been involved in developing a method of evaluating the suitability of dents in pipelines for continued service. The majority of the work involved the development of a method of modeling the stresses within a dent using Finite Element Analysis (FEA). The development and validation of this model was completed by Fleet Technology Limited (FTL) through several projects sponsored by Enbridge, which included field trials and comparisons to previously published data. This model combined with proven fracture mechanics theory provides a method of determining a predicted life of a dent based on either the past or future operating conditions of the pipeline. CSA Standard Z662 – Oil and Gas Pipeline Systems provides criteria for the acceptability of dents for continued service. There have been occurrences, however, where dents that meet the CSA acceptability criteria have experienced failure. The dent model is being used to help define shape characteristics in addition to dent depth, the only shape factor considered by CSA, which contribute to dent failure. The dent model has also been utilized to validate the accuracy of current In-Line Inspection techniques. Typically a dent will lose some of its shape as the overburden is lifted from the pipeline and after the indentor is removed. Often there can be a dramatic “re-rounding” that will occur. The work included comparing the re-rounded dent shapes from a Finite Element model simulating the removal of the constraint on the pipe to the measured dent profile from a mold of the dent taken in the field after it has been excavated. This provided a measure of the accuracy of the tool. This paper will provide an overview of Enbridge’s dent management program, a description of the dent selection process for the excavation program, and a detailed review of the ILI validation work.

scholarly journals A Buckling Flexure-Based Force-Limiting Mechanism

2019 ◽  
Vol 11 (4) ◽  
Author(s):  
Jonathan Slocum ◽  
Kenneth Kamrin ◽  
Alexander Slocum
Keyword(s):  
Finite Element ◽  
Design Methodology ◽  
Structural Model ◽  
Cost Effective ◽  
Element Model ◽  
Single Shot ◽  
Excessive Force ◽  
Molding Machine ◽  
Preliminary Model ◽  
Wide Range

A force-limiting buckling flexure has been created which can be used in a wide range of applications where excessive force from an implement can cause harm or damage. The buckling flexure is monolithic, contains no electronics, and can be manufactured using a single shot in an injection molding machine, making it cost effective. In this paper, the design of the flexure is applied to a force-limiting toothbrush as a design study to show its application in a real-world technology. An overview of the buckling flexure is presented, and a structural model is presented to predict when the flexure will elastically buckle. Flexures of different geometries were tested and buckled. The data show that the model can predict buckling of the flexure with an error of 20.84%. A finite element model was also performed which predicts buckling of the flexure within an error of 25.35%. Furthermore, a preliminary model is presented which enables the design of the buckling beam’s displacement, such that the total breakaway deformation can be maximized, making sensing the sudden deformation easier to detect. As part of the application of the buckling flexure, an ergonomic, injection moldable toothbrush was created with the flexure built into the neck of the brush. When the user applies too much force while brushing, the flexure gives way and alerts the user when they have applied too much force; when the user lets off the force, the brush snaps back to its original shape. This design methodology is generalized and can be utilized in other force limited applications where an injection-moldable, pre-set force, and purely mechanical breakaway device is desired.

Finite Element Analysis of Structural Strength of Concrete Mixing Truck’s Frame

2014 ◽  
Vol 945-949 ◽  
pp. 1143-1149
Author(s):  
Hai Xia Sun ◽  
Hua Kai Wei ◽  
Xiao Fang Zhao ◽  
Jia Rui Qi
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Model ◽  
Structural Strength ◽  
Element Model ◽  
Basic Element ◽  
Operating Conditions ◽  
Frame Structure ◽  
Element Analysis ◽  
The Finite Element Model

The finite element model of the concrete mixing truck’s frame is builded by using shell as basic element, and the process of building the finite element model of the balance suspension is introduced in detail. Based on this, frame’s stress on five types of typical operating conditions are calculated by using the finite element analysis software, NASTRAN, and results can show the dangerous position and the maximum stress position on the frame. The analysis result on structural strength can provide the basis for further improving the frame structure.

Finite Element Analysis on Behavior of the Joint with Steel Tube Confined Concrete (STCC) Column to Reinforced Concrete Beam

2011 ◽  
Vol 243-249 ◽  
pp. 527-530 ◽  
Author(s):  
Wen Da Wang ◽  
Zhi Feng Guo ◽  
Yan Li Shi
Keyword(s):  
Finite Element ◽  
Mechanical Performance ◽  
Material Model ◽  
Element Model ◽  
Reinforced Concrete Beam ◽  
Steel Tube ◽  
Confined Concrete ◽  
Composite Joints ◽  
Element Analysis ◽  
Composite Joint

The steel tube confined concrete (STCC) column exhibits excellent mechanical performance. A 3-D finite element model (FEM) using ABAQUS was established to simulate the performance of the composite joints with STCC column and RC beam. Accurate material model, rational element type, and solution method were discussed. Some STCC columns and composite joints with concrete-filled steel tubular (CFST) column and STCC column were modeled based on the model, respectively. The results from FEM are good agreement with the test results. The mechanism of the composite joint was investigated based on the FEM.

Investigation of Broken Cut Spikes on Elastic Fastener Tie Plates Using an Integrated Simulation Method

2018 ◽  
Author(s):  
Yin Gao ◽  
Mike McHenry ◽  
Brad Kerchof
Keyword(s):  
Finite Element ◽  
Element Model ◽  
Simulation Method ◽  
Operating Conditions ◽  
Analysis Model ◽  
Element Analysis ◽  
Integrated Simulation ◽  
Multibody Model ◽  
Track System ◽  
High Degree

Cut spike fasteners, used with conventional AREMA rolled tie plates and solid sawn timber ties, are the most common tie and fastener system used on North American freight railroads. Cut spikes are also used to restrain tie plates that incorporate an elastic rail fastener — that is, an elastic clip that fastens the rail to the tie plate. Elastic fasteners have been shown to reduce gage widening and decrease the potential for rail roll compared to cut spike-only systems. For this reason, elastic fastener systems have been installed in high degree curves on many railroads. Recent observations on one Class I railroad have noted broken cut spikes when used with these types of tie plates in mountainous, high degree curve territory. Broken screw spikes and drive spikes on similar style plates have also been observed. In this paper, a simulation method that integrates a vehicle-track system dynamics model, NUCARS®, with a finite element analysis model is used to investigate the root causes of the broken spikes. The NUCARS model consists of a detailed multibody train, wheel-rail contact parameters, and track model that can estimate the dynamic loading environment of the fastening system. For operating conditions in tangent and curve track, this loading environment is then replicated in a finite element model of the track structure — ties, tie plates, and cut spikes. The stress contours of the cut spikes generated in these simulations are compared to how cut spikes have failed in revenue service. The tuning and characterization of both the vehicle dynamics multibody model and the finite element models are presented. Additionally, the application of this approach to other types of fastening systems and spike types is discussed. Preliminary results have identified a mechanism involving the dynamic unloading of the tie plate-to-tie interface due to rail uplift ahead of the wheel and the resulting transfer of net longitudinal and lateral forces into the cut spikes. Continued analysis will attempt to confirm this mechanism and will focus on the severity of these stresses, the effect of increased grade, longitudinal train dynamics, braking forces, and curvature.

NONLINEAR FINITE ELEMENT ANALYSIS OF FRP STRENGTHENED RC BEAMS

2015 ◽  
Vol 2 (1) ◽  
Author(s):  
Prabin Pathak ◽  
Y. X. Zhang
Keyword(s):  
Finite Element ◽  
Plastic Material ◽  
Experimental Studies ◽  
Material Model ◽  
Element Model ◽  
Steel Reinforcement ◽  
Elastic Model ◽  
Fe Model ◽  
Rc Beams ◽  
Element Analysis

A simple, accurate and efficient finite element model is developed in ANSYS for numerical modelling of the nonlinear structural behavior of FRP strengthened RC beams under static loading in this paper. Geometric nonlinearity and material non-linear properties of concrete and steel rebar are accounted for this model. Concrete and steel reinforcement are modelled using Solid 65 element and Link 180 element, and FRP and adhesive are modelled using Shell 181element and Solid 45 element. Concrete is modelled using Nitereka and Neal’s model for compression, and isotropic and linear elastic model before cracking with strength gradually reducing to zero after cracking for tension. For steel reinforcement, the elastic perfectly plastic material model is used. FRPs are assumed to be linearly elastic until rupture and epoxy is assumed to be linearly elastic. The new FE model is validated by comparing the computed results with those obtained from experimental studies.

Finite Element Analysis of Synchronous Belt Tooth Failure

1993 ◽  
Vol 207 (2) ◽  
pp. 145-153 ◽  
Author(s):  
K W Dalgarno ◽  
A J Day ◽  
T H C Childs
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Material Model ◽  
Element Model ◽  
Element Analysis ◽  
Finite Element Program ◽  
Interface Elements ◽  
Dimensional Finite Element ◽  
Element Program ◽  
Critical Strains

This paper describes a finite element analysis of a synchronous belt tooth under operational loads and conditions with the objective of obtaining a greater understanding of belt failure by tooth root cracking through an examination of the strains within the facing fabric in the belt. The analysis used the ABAQUS finite element program, and was based on a two-dimensional finite element model incorporating a hyperelastic material model for the elastomer compound. Contact between the belt tooth face and the pulley groove was modelled using surface interface elements which allowed only compression and shear forces at the contact surfaces. It is concluded that the critical strains in the facing fabric of the belt, and therefore the belt life, are largely determined by the tangential loading condition on the belt teeth.

The interfacial heat transfer coefficient in hot die forging of titanium alloy

1998 ◽  
Vol 212 (6) ◽  
pp. 485-496 ◽  
Author(s):  
Z M Hu ◽  
J W Brooks ◽  
T A Dean
Keyword(s):  
Heat Transfer ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Titanium Alloy ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Hot Forging ◽  
Element Model ◽  
Interfacial Heat Transfer Coefficient ◽  
Element Analysis

An investigation of die temperature changes and the heat transfer coefficient during hot forging of titanium alloy has been carried out using experiments and a thermal-plastic coupled finite element analysis. Hot Ti-6A1–4V rings were forged between two heated flat dies made of Inconel alloy IN718. The bottom die was instrumented with high-response thermocouples on its surface and subsurface. The recorded temperatures were analysed and used to determine the interface heat transfer coefficient between the die and the workpiece in conjunction with the thermal-plastic coupled finite element analysis using a reverse algorithm. The coefficients determined were then used in a finite element model for the analysis of the upsetting process and the results produced were in good agreement with the experimental data.

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