scholarly journals Numerical Analysis of the Forming Process of Head Toothing in Rolling Extrusion on a Shaft from Aluminum Alloy 7075 / Analiza Numeryczna Kształtowania Uzębienia Czołowego W Procesie Przepychania Obrotowego Na Wałku Ze Stopu Aluminium 7075

2015 ◽  
Vol 60 (4) ◽  
pp. 2739-2742 ◽  
Author(s):  
J. Bartnicki ◽  
J. Tomczak
Keyword(s):  
Aluminum Alloy ◽  
Numerical Analysis ◽  
Material Flow ◽  
Numerical Models ◽  
Numerical Calculations ◽  
Technological Parameters ◽  
Forming Process ◽  
Real Material ◽  
Aluminum Alloy 7075 ◽  
Extrusion Technology

This paper presents the forming method of head toothing with the application of rolling extrusion technology. Tools numerical models were used in numerical calculations. The presented numerical results concern metals flow kinematics, distributions of stresses and strains. Determined in the process technological parameters of head toothing forming allow foreseeing real material flow in the experiment planned for conducting.

scholarly journals Numerical Analysis of the Cross-Wedge Rolling Process by Means of Three Tools of Stepped Shafts From Aluminum Alloy 7075

2015 ◽  
Vol 60 (1) ◽  
pp. 433-435 ◽  
Author(s):  
J. Bartnicki ◽  
J. Tomczak ◽  
Z. Pater
Keyword(s):  
Aluminum Alloy ◽  
Numerical Analysis ◽  
Crucial Role ◽  
Rolling Process ◽  
Numerical Calculations ◽  
Cross Wedge Rolling ◽  
Damage Criterion ◽  
Designed Experiment ◽  
The Cross ◽  
Aluminum Alloy 7075

Abstract This paper presents results of numerical calculations for the rolling process by means of three tools of stepped shafts from aluminum alloy 7075. Forming with the usage of tools with three different wedge spreading angles underwent analysis. In the paper, the obtained distributions of stresses, strains and Cockcroft-Latham damage criterion were given. Moreover, the influence of the wedge spreading angle on shape faults presence in the obtained product was determined. At the same time, the force parameters, which play a crucial role in the designed experiment, were analyzed.

scholarly journals Cold Forging Effect on the Microstructure of Motorbike Shock Absorbers Fabricated by Tube Forming in a Closed Die

2021 ◽  
Vol 11 (5) ◽  
pp. 2142
Author(s):  
Trung-Kien Le ◽  
Tuan-Anh Bui
Keyword(s):  
Material Flow ◽  
Cold Forging ◽  
Technological Parameters ◽  
Forming Process ◽  
Tube Forming ◽  
Shock Absorbers ◽  
Thin Walled Tube ◽  
Thin Walled ◽  
Quality Of Products ◽  
Forming Defects

Motorbike shock absorbers made with a closed die employ a tube-forming process that is more sensitive than that of a solid billet, because the tube is usually too thin-walled to conserve material. During tube forming, defects such as folding and cracking occur due to unstable tube forming and abnormal material flow. It is therefore essential to understand the relationship between the appearance of defects and the number of forming steps to optimize technological parameters. Based on both finite element method (FEM) simulations and microstructural observations, we demonstrate the important role of the number and methodology of the forming steps on the material flow, defects, and metal fiber anisotropy of motorbike shock absorbers formed from a thin-walled tube. We find limits of the thickness and height ratios of the tube that must be held in order to avoid defects. Our study provides an important guide to workpiece and processing design that can improve the forming quality of products using tube forming.

Effective Forming Processes of Hub Forging from Aluminum Alloy AlCu2SiMn

2013 ◽  
Vol 773-774 ◽  
pp. 115-118
Author(s):  
Andrzej Gontarz
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Material Flow ◽  
Theoretical Research ◽  
Material Consumption ◽  
Forming Process ◽  
Metal Forming Process ◽  
Large Material

This paper presents results of theoretical and experimental research works on metal forming process of a hub. A typical technology of forging on hammer of this part with flash was discussed. Two new processes of a hub forging were proposed, characterized by large material savings in comparison with typical technology. The first process is based on forming without flash of a forging with axial cavity. The second one is connected with forming of forging from pipe billet. The realization of these processes is possible at the application of a press with three movable working tools. Theoretical research works were done on the basis of simulations by means of finite element method. Simulations were made mainly in order to determine kinematics of material flow in forging processes and precision of shape and dimensions of obtained products. The first of the proposed processes was experimentally verified and a product of good quality was obtained. Material consumption of the analyzed processes and other factors acting on their effectiveness were also compared.

Numerical Simulation of Bulging Process of Aluminum Alloy Sheet

2013 ◽  
Vol 327 ◽  
pp. 112-116 ◽  
Author(s):  
Mao Ting Li ◽  
Yong Zhang ◽  
Chui You Kong
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Thickness Distribution ◽  
Superplastic Forming ◽  
Alloy Sheet ◽  
Pressure Loading ◽  
Forming Process ◽  
Element Analysis ◽  
Danger Zone ◽  
Linear Finite Element

Basing on software MSC. Marc of non-linear finite element analysis, the article has studied the material flow in the process of aluminum alloy superplastic gas bulging forming. By analyzing of the thickness distribution of the molding member it confirm the danger zone in the forming process. By analyzing of pressure loading curve influence on forming part. Because the aluminum alloy is widely used in the industrial departments, it is supposed to improve the ability of forming ability of aluminum alloy by researching the superplastic forming.

The Analysis of Multistage Deep Drawing of AA5754 Aluminum Alloy

2010 ◽  
Vol 55 (4) ◽  
pp. 1173-1184 ◽  
Author(s):  
M. Paćko ◽  
M. Dukat ◽  
T. Śleboda ◽  
M. Hojny
Keyword(s):  
Aluminum Alloy ◽  
Numerical Analysis ◽  
Numerical Simulations ◽  
Contact Surface ◽  
Deep Drawing ◽  
Material Flow ◽  
Drawing Process ◽  
Deep Drawing Process ◽  
Side Walls ◽  
Good Agreement

The Analysis of Multistage Deep Drawing of AA5754 Aluminum AlloyThis work is focused on the multistage deep drawing of AA5754 aluminum alloy box-type part with flange. Both experimental and numerical analysis were performed in this study to predict causes of contraction and cracking occurring in deformed product in respect to the changes of friction conditions on tool-drawn part contact surface. The numerical simulations were performed using eta/DYNAFORM software and LS-DYNA® solver. The research showed, that the results of the simulation are in very good agreement with the results of the real multistage deep drawing processes. Moreover, this study showed, that proper conditions of friction on the tool-drawpiece contact surface is crucial for the correctness of the analyzed deep drawing process. Too large friction can restrict the material flow, particularly along the edge connecting the bottom and side-walls of the drawpiece, causing wrinkling and cracking.

Simulation Study on Influence of Forming Process Parameters on Backward Extrusion Height of 6061 Aluminum-Alloy Wheel

2011 ◽  
Vol 121-126 ◽  
pp. 363-366
Author(s):  
Lu Li ◽  
Fang Wang
Keyword(s):  
Aluminum Alloy ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Forming Process ◽  
6061 Aluminum Alloy ◽  
Backward Extrusion ◽  
Punch Speed ◽  
Alloy Wheel ◽  
Forming Temperature ◽  
Extrusion Technology

Backward extrusion process of aluminum-alloy wheel forging is analyzed by the finite element method. The influence of punch speed and forming temperature on the backward extrusion height of 6061 aluminum alloy wheel is discussed. Studies show that the backward extrusion height increases with increasing forming temperature, and with decreasing punch speed at the same deformation load. It is indicated that when the ranges of forming temperature is from 450 to 500°C and the punch speed is 0.5-1 mm/s, the aluminum alloy wheel has the optimal forming quality. The analysis and conclusions in this paper are helpful in developing the hot extrusion technology specification of 6061 aluminum alloy.

Effective Forming Processes of Hub Forging from Aluminum Alloy AlCu2SiMn

2013 ◽  
Vol 572 ◽  
pp. 265-268
Author(s):  
Andrzej Gontarz
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Material Flow ◽  
Theoretical Research ◽  
Material Consumption ◽  
Forming Process ◽  
Metal Forming Process ◽  
Large Material

This paper presents results of theoretical and experimental research works on metal forming process of a hub. A typical technology of forging on hammer of this part with flash was discussed. Two new processes of a hub forging were proposed, characterized by large material savings in comparison with typical technology. The first process is based on forming without flash of a forging with axial cavity. The second one is connected with forming of forging from pipe billet. The realization of these processes is possible at the application of a press with three movable working tools. Theoretical research works were done on the basis of simulations by means of finite element method. Simulations were made mainly in order to determine kinematics of material flow in forging processes and precision of shape and dimensions of obtained products. The first of the proposed processes was experimentally verified and a product of good quality was obtained. Material consumption of the analyzed processes and other factors acting on their effectiveness were also compared.

Numerical Analysis of Rolling Extrusion Process of a Toothed Shaft from Titanium Alloy Ti6Al4V

2014 ◽  
Vol 622-623 ◽  
pp. 1215-1220
Author(s):  
Jarosław Bartnicki ◽  
Janusz Tomczak ◽  
Zbigniew Pater
Keyword(s):  
Titanium Alloy ◽  
Numerical Analysis ◽  
Metal Flow ◽  
Fem Analysis ◽  
Extrusion Process ◽  
Technological Parameters ◽  
Forming Process ◽  
Radial Forces ◽  
Titanium Alloy Ti6al4v ◽  
Deform 3D

This paper presents results of numerical calculations of rolling extrusion process of a toothed shaft made from titanium alloy Ti6Al4V. FEM analysis was conducted applying the software DEFORM 3D for the process chosen technological parameters. The kinematics of metal flow in the area of the formed teeth was analyzed. Distributions of stresses, strains and temperatures during teeth forming were determined. Calculated values of axial and radial forces and moments acting on rotating roll tools allow for designing of tools for experimental verification of the designed forming process.

scholarly journals Numerical Analysis of Stress Intensity Factor in Specimens with Different Fillet Geometry Subjected to Bending

2018 ◽  
Vol 12 (1) ◽  
pp. 38-43
Author(s):  
Janusz Lewandowski ◽  
Dariusz Rozumek
Keyword(s):  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Numerical Analysis ◽  
Intensity Factor ◽  
Stress Ratio ◽  
Numerical Models ◽  
Stress Component ◽  
Numerical Calculations ◽  
Stress Intensity Factor Range ◽  
Cyclic Bending

AbstractThe article presents the maps of xx stress component and compares values of analytical and numerical calculations for the stress intensity factor range of welded specimens with fillet welds which subjected to cyclic bending. The tests were performed under constant value of moment amplitude Ma= 9.20 N·m and stress ratio R = σmin/ σmax= −1. The specimens were made of drag steel rod S355. The specimens were solid and welded. The numerical models were simulated with ABAQUS suite and numerical calculations performed with FRANC3D software.

scholarly journals Numerical modelling of T-pipe joints forming

2018 ◽  
Vol 190 ◽  
pp. 04005
Author(s):  
Jarosław Bartnicki
Keyword(s):  
Numerical Modelling ◽  
Experimental Verification ◽  
Metal Flow ◽  
Industrial Applications ◽  
Numerical Calculations ◽  
Wide Scope ◽  
Technological Parameters ◽  
Forming Process ◽  
Damage Criterion ◽  
Pipe Joints

This paper presents results of numerical calculations of T-pipe joints (tee) forming process for a wide scope of industrial applications. FEM analyses were conducted for the chosen process technological parameters and tools designs. The kinematics of metal flow in the area of the formed flanges was analysed. Distributions of stresses, strains and damage criterion during forming were determined. Calculated values of forces and moments acting on tools and workpieces allow for designing of tools geometry for experimental verification of the proposed forming process.

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