Numerical Simulation and Experimental Verification of Disc Cutter Rings in Die Forging Process

2021 ◽  
Vol 13 (1) ◽  
pp. 131-139
Author(s):  
Luhan Hao ◽  
Tao Wang ◽  
Kangping Fu ◽  
Zhengyang Zhao ◽  
Yun Chen ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Element Model ◽  
Disc Cutter ◽  
Forging Process ◽  
Die Forging ◽  
Plastic Forming ◽  
Simulation Results ◽  
The Finite Element Model ◽  
Good Agreement

In order to study the forming law of the disc cutter ring in the independently researched die, the finite element model (FEM) of disc cutter ring for die forging has been established and the die forging process has been simulated by the plastic forming software. The metal flow field, temperature field, stress and strain field of the filling process were obtained by simulation. The exerted force of the die was also simulated and analyzed; thus, the die forging process was optimized. Based on the designed process parameters and simulation results, the experimental study on die forging forming of cutter ring was carried out. The comparison shows that the numerical simulation results are in good agreement with the experimental results, which proves that the die forging model of disc cutter ring in this paper is feasible.

Numerical Simulation on Thixo-Forging of Magnesium Matrix Composite

2011 ◽  
Vol 189-193 ◽  
pp. 2535-2538 ◽  
Author(s):  
Hong Yan ◽  
Wen Xian Huang
Keyword(s):  
Numerical Simulation ◽  
Matrix Composite ◽  
Metal Flow ◽  
Magnesium Matrix Composite ◽  
Magnesium Matrix ◽  
Simulation Based ◽  
Prior Literature ◽  
Simulation Results ◽  
Computer Numerical Simulation ◽  
Good Agreement

The thixo-forging of magnesium matrix composite was analyzed with computer numerical simulation based on rigid viscoplastic finite element method. The constitutive model of SiCp/AZ61 composite was established in our prior literature. Behavior of metal flow and temperature field were obtained. The differences between traditional forging and thixo-forging processes were analyzed. Results indicated that thixo-forging was better in filling cavity than forging. Simulation results were good agreement with experimental ones.

Numerical Simulation and Parameter Study of Radial Forging of Conical Tube

2020 ◽  
Vol 861 ◽  
pp. 514-518
Author(s):  
Xin Hai Zhao ◽  
Xin Bo Ren ◽  
Xing Chen Sun ◽  
Chao Zheng ◽  
Li Bin Song ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Reference Value ◽  
Element Model ◽  
Parameter Study ◽  
Radial Forging ◽  
Influence Of Process Parameters ◽  
Forming Quality ◽  
Forging Process ◽  
Radial Forging Process ◽  
The Finite Element Model

The cone tube is an important part of the circuit connector, which has high requirements for its forming quality. In this paper, the cone tube is taken as the object, the finite element model is established, the radial forging process of the cone tube is simulated, the influence of process parameters such as axial feed and friction on the thickness of the cone tube is studied, and the influence law is analyzed, which has certain reference value for the analysis of the forming law of the radial forging.

Application of Numerical Simulation in Closed-Die Forging Forming for Universal Joint Fork

2013 ◽  
Vol 441 ◽  
pp. 435-438
Author(s):  
Jin Yang ◽  
Ping Wang
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Metal Flow ◽  
Dimensional Accuracy ◽  
Element Model ◽  
Universal Joint ◽  
Forming Load ◽  
Die Forging ◽  
Die Life ◽  
Closed Die Forging

A universal joint fork is one of the key parts of the automotive and tractor drive shaft system, which needs high requirements in dimensional accuracy and product quality. In this study, the numerical simulation analysis of closed-die forging of the universal joint fork was carried out using the rigid-visco-plastic finite element model. In view of formation, heat transfer and heating generation coupled, the variation rules of forming load, stress field and strain field were obtained. The numerical simulation results show that good process parameters conditions can effectively control forming load, enhance metal flow and improve die life.

Simulation and Microstructure Predict during Hot Die-Forging of Cast Mg-7.0Al-0.2Zn Magnesium Alloy

2010 ◽  
Vol 152-153 ◽  
pp. 1293-1296
Author(s):  
Li Hong Wu
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Strain Distribution ◽  
Forging Process ◽  
Die Forging ◽  
Comparison Results ◽  
Hot Die Forging ◽  
Good Agreement

Employing the dies for aluminum alloy parts, the hot die-forging forming and numerical simulation of semi-continuous casting Mg-7.0Al-0.4Zn (AZ70) were carried out. It was indicated that AZ70 has a worse fluidity during forging and is consequently difficult to fill fully compared to aluminum alloys. The microstructure of the AZ70 forgings is in good agreement with the strain distribution generated by simulation, and strain distribution can predict the microstructure evolution. The comparison results can give a guideline on developing forging process and controlling forgings quality of the AZ70 alloy.

Research on Prediction of Microstructure Evolution during Mobile Steering Arm Forging Process by FEM

2011 ◽  
Vol 130-134 ◽  
pp. 2326-2329
Author(s):  
Wen Lin Chen ◽  
Li Jing Peng ◽  
Yong Ma ◽  
Shao Yang Wang ◽  
Zhi Jie Li ◽  
...  
Keyword(s):  
Grain Size ◽  
Microstructure Evolution ◽  
Hot Forging ◽  
Element Model ◽  
Middle Part ◽  
Close Match ◽  
Forging Process ◽  
Simulation Results ◽  
Hot Forging Process ◽  
The Finite Element Model

In order to get high quality forgings, it is significant to predict the microstructure evolution during hot forging process accurately. In this study, a simulation model is built by combining FEM with the dynamic recrystallization model of 42CrMo, and the finite element model is proved to be reliable by a serial of upsetting deformation experiment. Then the distributions of microstructure evolution are obtained on upsetting process. Upsetting is beneficial to refine the grain size and drawing can make the distribution of grain size homogeneous. By comparing the simulation results with experiments, the distributions of microstructure are a close match in the middle part of steering arm. The forgings formed by this process have a good microstructure and have high comprehensive mechanical properties.

Effect of Extension Coefficient on H-Beam Deformation

2010 ◽  
Vol 20-23 ◽  
pp. 1199-1204 ◽  
Author(s):  
Xian Zhang Feng ◽  
Qun Li
Keyword(s):  
Initial Conditions ◽  
Metal Flow ◽  
Element Model ◽  
Deformation Degree ◽  
Simulation Based ◽  
Simulation Results ◽  
Contact Situation ◽  
H Beam ◽  
The Finite Element Model ◽  
The Web

In order to research the effect of metal flow between web and flange, the concept of extension coefficient used to judge the deformation degree for rolling H-beam, through the method of changing the extension coefficient, the finite element model was established by the platform of CAD software. Defining boundary conditions, geometric properties and contact situation, and input initial conditions based on the model. It can gain the displacement cloud map and displacement curves of the model by computer simulation. Based on the simulation results, studying the effects of different extension coefficient on metal flowing between flange and web, as well as the qualitative relations of extension coefficient between flange and web. The results showed that with the enlargement of extension coefficient, the metal flowing between web and flange would be more obvious, while the definite feature relation between web and flange can get better effects with the condition that the extension coefficient of flange is large than that of the web.

Research on Closed Die Forging Process of Car Steering Knuckle

2008 ◽  
Vol 575-578 ◽  
pp. 204-209 ◽  
Author(s):  
De Ying Zhao ◽  
Lian Dong Zhang ◽  
Hui Xue Sun
Keyword(s):  
Numerical Simulation ◽  
High Energy ◽  
Extrusion Pressure ◽  
Forming Process ◽  
Forging Process ◽  
Dimensional Precision ◽  
Die Forging ◽  
Closed Die Forging ◽  
Plastic Forming ◽  
Die Extrusion

Steering knuckle, which has strict requirements with regard to dimensional precision and quality, is a key component in cars. Conventional plastic forming methods are involved with intricate procedures and high energy consumptions. Normally, a 40 MN hot die forging press or a 100 KJ electro-hydraulic hammer is required to produce the steering knuckle. Closed die forging, which is a new precision forming technology developed in recent years, has some virtues, such as good mechanical properties, easy to form and improving of metal plastic deformation. Aiming at Jetta steering knuckle in this paper, the technology of two forging steps in one heat is presented. This technology is mainly composed of precision pre-forging, which is a closed die extrusion with the extrusion belt, and open finish-forging. The pre-forging process and finish-forging process are numerically simulated using the FEM software DEFORM-3D. For the closed die extrusion forming process, which is the key component of the technology, some key problems were researched, such as the flowing and filling regularity, extrusion-belt length, punch size, punch movement, lubrication and the relationship between the clamping pressure and the extrusion pressure. For the finish-forging process, the flowing and filling regularity of the finish-forging part was studied to verify the correct shape and dimension of the pre-forging part. Numerical simulation with regard to the pre-forging process shows that the closed die forging can not only help to form the pre-forging part, but also decrease the extrusion pressure to be less than 8 MN, extend the mould’s service life and increase the utilization ratio of materials to be more than 75%. Numerical simulation of the finish-forging process shows that the pre-forging part design is rational. In addition, the forging experiments were carried out using the dies designed in particular. The experiments show that the technology is feasible and can markedly improve the mechanical property of the forging piece.

Inward Flow of Surface Materials at Back-Ends of Billets During Al-Extrusion, Part 1: A Finite Element Model

1999 ◽  
Vol 121 (3) ◽  
pp. 321-327 ◽  
Author(s):  
Jin Hou
Keyword(s):  
Finite Element ◽  
Surface Layer ◽  
Outer Surface ◽  
Metal Flow ◽  
Hot Extrusion ◽  
Element Model ◽  
Surface Material ◽  
Rigid Plastic ◽  
Simulation Results ◽  
Good Agreement

In hot extrusion of Al-profiles, the billet-container boundary is characterized by the sticking condition. The outer surface layer of the billet is stuck to the container wall. At the back-end of the billet, the metal flow is complicated. The surface material, which is initially stuck to the wall, will be scraped away by the pad and flow inward into the billet. This kind of inward flow of surface material is usually undesirable and it is important to control such flow so that no surface material should be found in extruded profiles. In order to study this phenomenon, a model is proposed for the metal flow at the back-end, in which the rigid-plastic FEM is used. A computer program FEMBA has been developed based on the model. The simulation results are in qualitatively good agreement with experiments.

scholarly journals Numerical Simulation and Experimental Study on Axial Stiffness and Stress Deformation of the Braided Corrugated Hose

2021 ◽  
Vol 11 (10) ◽  
pp. 4709
Author(s):  
Dacheng Huang ◽  
Jianrun Zhang
Keyword(s):  
Numerical Simulation ◽  
Geometric Model ◽  
Equivalent Stress ◽  
Element Model ◽  
Maximum Error ◽  
Structural Features ◽  
Axial Stiffness ◽  
Frictional Stress ◽  
Maximum Equivalent Stress ◽  
Simulation Results

To explore the mechanical properties of the braided corrugated hose, the space curve parametric equation of the braided tube is deduced, specific to the structural features of the braided tube. On this basis, the equivalent braided tube model is proposed based on the same axial stiffness in order to improve the calculational efficiency. The geometric model and the Finite Element Model of the DN25 braided corrugated hose is established. The numerical simulation results are analyzed, and the distribution of the equivalent stress and frictional stress is discussed. The maximum equivalent stress of the braided corrugated hose occurs at the braided tube, with the value of 903MPa. The maximum equivalent stress of the bellows occurs at the area in contact with the braided tube, with the value of 314MPa. The maximum frictional stress between the bellows and the braided tube is 88.46MPa. The tensile experiment of the DN25 braided corrugated hose is performed. The simulation results are in good agreement with test data, with a maximum error of 9.4%, verifying the rationality of the model. The study is helpful to the research of the axial stiffness of the braided corrugated hose and provides the base for wear and life studies on the braided corrugated hose.

scholarly journals Numerical Simulations of V-Shaped Plates Subjected to Blast Loadings: A Validation Study

2016 ◽  
Vol 10 (11) ◽  
pp. 203
Author(s):  
Mohd Zaid Othman ◽  
Qasim H. Shah ◽  
Muhammad Akram Muhammad Khan ◽  
Tan Kean Sheng ◽  
M. A. Yahaya ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Numerical Simulations ◽  
Variable Mass ◽  
Blast Loading ◽  
Experimental Results ◽  
Average Difference ◽  
Simulation Results ◽  
Blast Loadings ◽  
Carrier Vehicle ◽  
Good Agreement

A series of numerical simulations utilizing LS-DYNA was performed to determine the mid-point deformations of V-shaped plates due to blast loading. The numerical simulation results were then compared with experimental results from published literature. The V-shaped plate is made of DOMEX 700 and is used underneath an armour personal carrier vehicle as an anti-tank mine to mitigate the effects of explosion from landmines in a battlefield. The performed numerical simulations of blast loading of V-shaped plates consisted of various angles i.e. 60°, 90°, 120°, 150° and 180°; variable mass of explosives located at the central mid-point of the V-shaped vertex with various stand-off distances. It could be seen that the numerical simulations produced good agreement with the experimental results where the average difference was about 26.6%.

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