Investigation on Sheet Hydroforming Process of Titanium/Aluminum Clad Metal Housing

2010 ◽  
Author(s):  
Huang-Chi Tseng ◽  
Zong-Chun Wu ◽  
Chinghua Hung ◽  
Ming-Hu Lee
Keyword(s):  
Finite Element ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Drawing Ratio ◽  
Explicit Finite Element ◽  
Sheet Hydroforming ◽  
High Surface Quality ◽  
Titanium Aluminum ◽  
Significant Process ◽  
Hydroforming Process

In this research, the sheet hydroforming process (SHF) was adopted to form a Ti/Al clad metal housing with complex shape. Nowadays, SHF has been widely accepted for the production of components characterized by high surface quality, precise dimensional accuracy together with high drawing ratio. For investigating the formability of the Ti/Al clad metal housing through SHF, the concept of virtual film were developed with explicit finite element method. First, the simulation model was verified by comparing the deformation of the blank obtained from experiments. Through finite element simulations, several significant process parameters such as holding force, tooling geometry, blank dimensions, single-stage (with pre-bulging effect) and multi-stages SHF were analyzed for improving formability of the Ti / Al clad metal housing during SHF.

An Experimental and Numerical Study to Analysis and Design of Sheet Hydroforming Process for an Automobile Fender Shell

2006 ◽  
Author(s):  
Mohammad Habibi Parsa ◽  
Payam Darbandi
Keyword(s):  
Finite Element ◽  
Numerical Study ◽  
Fluid Pressure ◽  
Finite Element Program ◽  
New Approach ◽  
Explicit Finite Element ◽  
Sheet Hydroforming ◽  
Analysis And Design ◽  
Hydroforming Process ◽  
Element Program

A new approach for manufacturing of shell fender is proposed and has been examined numerically and experimentally. The new suggested method is based on sheet hydroforming process, which has a lot of advantages over conventional deep drawing process. After defining the shape of initial blank using an inverse finite element program, numerical evaluation of the proposed sheet hydroforming process for production of shell fender has been carried out using an explicit finite element code considering fluid pressure, boundary conditions and tools. Then experimental evaluation has been carried out using down sized specimen and the results have been compared with results of previous simulations. It has been shown that there are similar trends between finite element and experimental results.

Benchmark test artifacts for selective laser melting – a critical review

2021 ◽  
Vol 15 ◽  
Author(s):  
Weishi Li ◽  
Kuanting Wang ◽  
Shiaofen Fang
Keyword(s):  
Selective Laser Melting ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Melting Process ◽  
Design Guidelines ◽  
Laser Melting ◽  
Specific Test ◽  
Benchmark Test ◽  
High Surface Quality ◽  
Machine Performance

Background: Selective laser melting is the best-established additive manufacturing technology for high-quality metal part manufacturing. However, the widespread acceptance of the technology is still underachieved, especially in critical applications, due to the absence of a thorough understanding of the technology, although several benchmark test artifacts have been developed to characterize the performance of selective laser melting machines. Objective: The objective of this paper is to inspire new designs of benchmark test artifacts to understand the selective laser melting process better and promote the acceptance of the selective laser melting technology. Method: The existing benchmark test artifacts for selective laser melting are analyzed comparatively, and the design guidelines are discussed. Results: The modular approach should still be adopted in designing new benchmark test artifacts in the future, and task-specific test artifacts may also need to be considered further to validate the machine performance for critical applications. The inclusion of the design model in the manufactured artifact, instead of the conformance to the design specifications, should be evaluated after the artifact is measured for the applications requiring high-dimensional accuracy and high surface quality. Conclusion: The benchmark test artifact for selective laser melting is still under development, and a breakthrough of the measuring technology for internal and/or inaccessible features will be beneficial for understanding the technology.

Influence of Manufacturing Process on the Fatigue Strength of Gears

2014 ◽  
Vol 1018 ◽  
pp. 269-276
Author(s):  
Andrea Reiß ◽  
Ulf Engel
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

Optimization of Pressure Path in Sheet Hydroforming Process Using Artificial Intelligence and Simulated Annealing

2014 ◽  
Vol 622-623 ◽  
pp. 772-779 ◽  
Author(s):  
Amirreza Yaghoobi ◽  
Mohammad Bakhshi-Jooybari ◽  
Abdolhamid Gorji ◽  
Hamid Baseri
Keyword(s):  
Neural Network ◽  
Finite Element ◽  
Simulated Annealing ◽  
Network Model ◽  
Neural Network Model ◽  
Critical Region ◽  
Element Model ◽  
Sheet Hydroforming ◽  
The Neural Network ◽  
Hydroforming Process

The success of sheet hydroforming process largely depends on the loading pressure path. Pressure path is one of the most important parameters in sheet hydroforming process. In this study, a combination of finite element simulation, artificial intelligence and simulated annealing optimization have been utilized to optimize the pressure path in producing cylindrical-spherical parts. In the beginning, the finite element model was verified based on laboratory experimental results. The experiments were designed and a radial basis neural network model was developed using data generated from verified finite element model to predict the thickness in the critical region of the product. Results indicated that the neural network model could be applied successfully to predict the sheet thickness in the critical region. In addition, the neural network model was used as a fitness function in simulated annealing algorithm to minimize the thickening in the above mentioned critical region. The final results showed that utilization of the optimized pressure path yields good thickness distribution of the part.

Barrel Chamber Polishing, Using Electrochemical Theories

2007 ◽  
Vol 364-366 ◽  
pp. 272-279
Author(s):  
Ramezan Ali Mahdavinejad
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Point Of View ◽  
Electrochemical Polishing ◽  
Machining Time ◽  
High Surface Quality ◽  
Surface Polishing ◽  
Complex Shapes ◽  
Complex Parts

Electrochemical polishing is a well-known method in finishing of complex shapes with high surface quality. Inner surface polishing of complex parts with high precision can also be easily done by this method. In this research, barrel chamber’s surface, with numerous serial surface angles, is analyzed so that, according to the various set ups, the optimized polishing parameters are obtained. The comparison between electrochemical polishing and conventional methods from this point of view, shows good advantages of this method, so that, the machining time is more than thirty times less and produces very high surface quality. Besides, the dimensional accuracy of the workpiece repeatability process in this polishing method is noticeable.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

The Innovative Production Developments in Sheet Hydroforming

2008 ◽  
Vol 575-578 ◽  
pp. 589-594
Author(s):  
Li Hui Lang ◽  
Hui Li Li ◽  
Xian Bin Zhou ◽  
Joachim Danckert ◽  
Yi Le Ghen
Keyword(s):  
Numerical Analysis ◽  
Surface Quality ◽  
Dimensional Accuracy ◽  
High Dimensional ◽  
Drawing Ratio ◽  
Sheet Hydroforming ◽  
Good Surface ◽  
Innovative Methods ◽  
Analysis Methods ◽  
The World

Sheet hydroforming has drawn much attention in the world because of its many advantages such as high drawing ratio, good surface quality and high dimensional accuracy, less springback etc. Based on the practical needs and the development of the hydroformed production, this paper presents the recent development of the sheet hydroforming and some innovative methods for the equipment, the processes and the numerical analysis methods have been introduced shortly.

scholarly journals Feasibility Study of Complex Sheet Hydroforming Process: Experimental and Modelling

2016 ◽  
Vol 716 ◽  
pp. 685-691 ◽  
Author(s):  
Mohamed Mohamed ◽  
David Carty ◽  
John Storr ◽  
Nicola Zuelli ◽  
Paul Blackwell ◽  
...  
Keyword(s):  
Finite Element ◽  
Feasibility Study ◽  
Fem Analysis ◽  
Close Correlation ◽  
Fe Model ◽  
Load Path ◽  
Sheet Hydroforming ◽  
Blank Design ◽  
Hydroforming Process ◽  
Experimental Trials

The application of finite element method (FEM) in the area of metal forming and material processing has significantly increased in the recent years. The presented study provides details of the development of a finite element modelling approach to form a part via sheet hydroforming (SHF) process. Both FEM analysis and experimental trials were introduced in this study to produce a complex shape component from Inconel 718 material. The FEM provides a robust feasibility study for forming this part in terms of blank design, load path and process design optimisation. The simulated hydroformed part was validated by performing experimental trials. The analysis demonstrated close correlation between the predicted FE model and the physical trial.

Numerical Simulation and Technology Optimization of Rear Oil Seal Bearing Die Castings Based on ProCAST

2011 ◽  
Vol 189-193 ◽  
pp. 4008-4013 ◽  
Author(s):  
Yi Dong ◽  
Xiao Ming Fan ◽  
Bin Liu
Keyword(s):  
Numerical Simulation ◽  
Production Efficiency ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Rejection Rate ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Casting Defects ◽  
High Surface Quality ◽  
Die Castings

In production,the Φ105 mm hole of rear oil seal bearing die castings often appear porosity, shrinkage and other defects , resulting in the parts to scrap. The existing gating system design of rear oil seal bearing die castings was improved , and the flow and temperature field of the two programs that before and after improvement were analyzed by ProCAST software. The simulation results predicted the casting defects, and the conclusion was consistent with the production. By using the improved process optimization, the rejection rate of die castings can be reduced effectively. Die casting is a chipless forming of casting with high casting dimensional accuracy, high surface quality and high production efficiency [1,2]. Therefore, it has developed rapidly in the automotive, communications and other industries. However, due to shrinkage, porosity and other reasons, leading to high rejection rate of castings. With the emergence of commercial casting simulation software, the casting production has been developed from semi empirical and semi theoretical onto theorization, quantification and controllable track[3-5]. In this paper, the casting defects of rear oil seal bearing is analyzed by using numerical simulation technology[6]. By optimizing the casting process, the casting quality is improved, and the rejection rate is reduced effectively.

Sign in / Sign up

Export Citation Format

Share Document