Using Pyramidal Three-Roll Bending Process to Improve the Quality of Seamed Cylinders

2013 ◽  
Author(s):  
Zhengkun Feng ◽  
Henri Champliaud
Keyword(s):  
Numerical Modeling ◽  
Numerical Model ◽  
Welding Process ◽  
Design And Optimization ◽  
Implicit Solvers ◽  
Roll Bending ◽  
Geometrical Quality ◽  
Bending Process

Mecano-welding can efficiently produce cylinders used in various industries. The pyramidal three-roll bending process is commonly used to produce a cylinder with non-seamed gap. However, there is a planar zone near the front and rear ends. This planar zone can be seamed with a welding process. In this paper, a numerical model is proposed to simulate the roll bending process and the welding process so that the geometrical quality of the bent cylinders can be improved. Explicit and implicit solvers are applied to the numerical modeling by using ANSYS/LS-DYNA software. The numerical model can provide a useful tool for design and optimization of the Mecano-welding process.

FEM Analysis of Mecano-Welding Process for Manufacturing Cylinders

2013 ◽  
Vol 549 ◽  
pp. 444-451
Author(s):  
Zheng Kun Feng ◽  
Henri Champliaud
Keyword(s):  
Numerical Modeling ◽  
Numerical Model ◽  
Welding Process ◽  
Fem Analysis ◽  
Ansys Software ◽  
Process Mechanism ◽  
Design And Optimization ◽  
Implicit Solvers ◽  
Roll Bending

Cylindrical components produced by mecano-welding process are widely used in industries. The mecano-welding process consists of a roll bending sub-process which can produce non-closed cylinders and a welding process which can seam gaps. This paper proposes a numerical model to simulate the process and to get better understanding of the process mechanism. Explicit and implicit solvers are applied to the numerical modeling by using LS-DYNA and ANSYS software. The numerical model can provide a useful tool for design and optimization of the mecano-welding process.

Numerical Modeling of Thermal Processes while Depositing Layers in Additive Production

2018 ◽  
Vol 938 ◽  
pp. 54-61
Author(s):  
M.A. Kuznetsov ◽  
M.A. Krampit ◽  
Artem V. Kryukov ◽  
T.S. Kust ◽  
N.V. Pavlov
Keyword(s):  
Numerical Modeling ◽  
Numerical Model ◽  
Distribution Patterns ◽  
Additive Technologies ◽  
Thermal Processes ◽  
Topical Issue ◽  
Additive Production ◽  
Entire Process ◽  
Substrate Plate

The up to date industry tends to introduce additive technologies in all fields of production, since their use furthers manufacturing of sufficiently qualitative products in a quite quick and economical way.As a consequence, it is still a topical issue how to control quality of the output products.The paper reports on a numerical model of thermal processes in a substrate plate and in a product while depositing.Temperature distribution patterns and a penetration form of a substrate plate are considered for the entire process of deposition.

scholarly journals EFFECT OF SPOT WELD POSITION VARIATION ON QUALITY OF AUTOMOBILE SHEET METAL PARTS

2013 ◽  
pp. 170-174
Author(s):  
M.P. MALI ◽  
K.H. INAMDAR
Keyword(s):  
Welding Process ◽  
The Body ◽  
Spot Weld ◽  
Spot Welds ◽  
Factors Affecting ◽  
Sheet Metal Parts ◽  
Geometrical Quality ◽  
Welding Sequence ◽  
Geometrical Factors

Resistance spot welding is the most preferred and widely used method for joining metal sheets in automotive and many other industrial assembly operations. The body of a car is typically joined by thousands of spot welds. One of the many geometrical factors affecting the final geometrical outcome of the metal part assemblies is the welding process considering welding sequence used when the parts are welded together. The spot welds guarantee the strength of the car, but their positions also affect the geometrical quality of subassemblies and the final product. In practice, the positions of the weld points often deviate from nominal position. By analyzing industrial scanning data, deviations of spot weld positions are found to be of magnitudes up to 19 mm. In this paper, the influence of variation in position of spot welds is investigated with respect to geometrical quality, by simulating and analyzing the geometrical variation of an A-pillar assembly.

scholarly journals Integrated Tolerance and Fixture Layout Design for Compliant Sheet Metal Assemblies

2021 ◽  
Vol 11 (4) ◽  
pp. 1646
Author(s):  
Abolfazl Rezaei Aderiani ◽  
Martin Hallmann ◽  
Kristina Wärmefjord ◽  
Benjamin Schleich ◽  
Rikard Söderberg ◽  
...  
Keyword(s):  
Production Cost ◽  
Integrated Design ◽  
Integrated Approach ◽  
Design And Optimization ◽  
Simulation Tools ◽  
Geometrical Quality ◽  
Compliant Assembly ◽  
Evolutionary Optimization Algorithms ◽  
Independent Design

Part tolerances and fixture layouts are two pivotal factors in the geometrical quality of a compliant assembly. The independent design and optimization of these factors for compliant assemblies have been thoroughly studied. However, this paper presents the dependency of these factors and, consequently, the demand for an integrated design of them. A method is developed in order to address this issue by utilizing compliant variation simulation tools and evolutionary optimization algorithms. Thereby, integrated and non-integrated optimization of the tolerances and fixture layouts are conducted for an industrial sample case. The objective of this optimization is defined as minimizing the production cost while fulfilling the geometrical requirements. The results evidence the superiority of the integrated approach to the non-integrated in terms of the production cost and geometrical quality of the assemblies.

scholarly journals Parametric Study on the Spring-Back Effect in AA5052 Alloy in the Course of Three-Point Roll Bending Process

2020 ◽  
Vol 14 (3) ◽  
pp. 128-134
Author(s):  
Viswanathan Shrinaath ◽  
Ramalingam Vairavignesh ◽  
Ramasamy Padmanaban
Keyword(s):  
Numerical Model ◽  
Statistical Model ◽  
Sheet Metal ◽  
Radius Of Curvature ◽  
Sheet Metals ◽  
Spring Back ◽  
Forming Load ◽  
Roll Bending ◽  
Bending Process ◽  
Experimental Trials

Abstract Three-point roll bending is one of the most common forming processes employed to obtain the desired radius of curvature in the sheet metal operations. Upon the removal of the forming load, the sheet metal deforms to a lesser extent than that of the required dimension. This phenomenon is termed as spring-back and is considered the most challenging areas of research in three-point roll bending of sheet metals. This study aims to develop a numerical model using HyperWorks and Radioss solver to understand the influence of load, the distance between the forming rollers, and its thickness on the spring-back effect in the course of three-point roll bending of sheet metal (AA5052). The results of the numerical model are validated with the results of the experimental trials. Besides, a statistical model is developed to relate the amount of spring-back with the three-point roll bending process parameters.

scholarly journals Numerical modeling of lower stratospheric Doppler ducted gravity waves over Jicamarca, Peru

2011 ◽  
Vol 11 (7) ◽  
pp. 19011-19027
Author(s):  
Z. Li ◽  
S. Naqvi ◽  
A. J. Gerrard ◽  
J. L. Chau ◽  
Y. Bhattacharya
Keyword(s):  
Numerical Modeling ◽  
Numerical Model ◽  
Gravity Waves ◽  
Lower Stratosphere ◽  
Physical Nature ◽  
High Quality ◽  
Data Set ◽  
Upper Troposphere ◽  
Wind Measurements

Abstract. Persistent jet structures along zonal and meridional fields, believed to be caused by stationary gravity waves, were detected in February 1999 in MST wind measurements of the troposphere and lower stratosphere over Jicamarca, Peru. Over a seven day span, two days of observations showed signatures of a Doppler ducted gravity wave in the upper troposphere/lower stratosphere. Herein we present the observations, their characteristics, and results of numerical simulations used to mimic these observed features. Though a fair replication of the observed ducted structure in the numerical model is found, the observed period of ~90 min is nonetheless longer than anticipated and raises concern as to the specific physical nature of the observed structures. However, given the high quality of the observations, we demonstrate that continued analysis of this data set and concurrent modeling will allow for a better understanding of Doppler ducts at high spatial and temporal resolution which can ultimately be applied to studies of mesospheric ducts and bores.

Sideways Movement of Strip in In-Plane Roll-Bending Process with Conical Rollers

2010 ◽  
Vol 154-155 ◽  
pp. 1419-1422
Author(s):  
Zhi Jun Li ◽  
He Yang ◽  
Heng Li ◽  
Jing Liu
Keyword(s):  
Maximum Deviation ◽  
Fe Simulations ◽  
Roll Bending ◽  
Bending Process ◽  
Deviation Ratio

As a result of unequal reduction, the sideways movement of the strip at the entry is occurred in in-plane roll-bending process with conical rollers. This will reduce the shape quality of the formed ring. To control the sideways movement, FE simulations with applying unilateral and bilateral guide planes are carried out by employing ABAQUS/Explicit code. The results show that, the strip moves towards the bottom end and scratches with guide plane at the trailing end if applying unilateral guide plane; the sideways movement can be controlled effectively with circularity of 0.993 and maximum deviation ratio of 12.5% for the formed ring if applying bilateral guide planes.

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