scholarly journals Optimization of Tool Geometric Parameters For a Small Fluteless Forming Tap (FFT)

2021 ◽  
Author(s):  
Ming-Chang Wu ◽  
Wei-Rong Jian ◽  
Ling-Sheng Hsu ◽  
chung-chen Tsao
Keyword(s):  
Aluminum Alloy ◽  
Element Model ◽  
Root Diameter ◽  
Geometric Parameters ◽  
Internal Thread ◽  
Filling Rate ◽  
Box Behnken Design ◽  
Functional Components ◽  
Minimum Torque ◽  
Made In

Abstract A small blind internal thread (SBIT) is used to firmly fasten some functional components to the cover of 3C electronic products. The small internal thread is made in a blind hole using a fluteless forming tap (FFT) that does not produce chips. However, the four geometric parameters (tool width (W), tooth root diameter (D2), front-end diameter (Df) and tooth angle (θ)) for the FFT affect the thread filling rate (f) and the minimum torque (T) for the tapping process. This study reports a Box-Behnken design (BBD) using DEFORM-3D (finite element model) and MINITAB (regression analysis) software to tap 7075-T6 aluminum alloy using a small FFT to achieve a repeatable thread filling rate and minimum torque. The experimental results show that the BBD accurately predicts and simulate the thread filling rate for tapping 7075-T6 aluminum alloy. The modelling software and the experimental design for this study can be used to optimize the design of tools that are used in industrial production.

Study the Influence of Geometric Parameters on Springback in T-Section Aluminum Alloy Window Trim Strip Sheets Forming

2018 ◽  
Vol 920 ◽  
pp. 70-76 ◽  
Author(s):  
Bao Hang Zhu ◽  
Yi Xi Zhao ◽  
Zhong Qi Yu ◽  
Hui Yan
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Geometric Parameters ◽  
Finite Element Models ◽  
Quality Requirement ◽  
Forming Process ◽  
Assembly Quality ◽  
Simulation Results ◽  
In The Beginning ◽  
Springback Control

The T-section aluminum alloy window trim strip sheets are used to improve vehicle appearance. As the mobile scenery line, these window trim strips with claws need high forming accuracy to meet good assembly quality requirement. The top portion of the T-section sheet is stamped to form an edge flange structure. Springback control is essential in forming process. In this paper, the influence of the window trim strip geometric parameters on forming springback is studied. Some finite element models of the process were built with the Dynaform software. The simulation results were verified experimentally. The main conclusions include as belows: The different heights of the stiffeners part in T-section change the stiffness of the part. Although the stiffeners part does not participate in the forming, it also has springback in the forming process. So, it is necessary to study the influence of the flanging part width (W) and the stiffeners part height (H) of the T-section on springback. We set W to 15 mm and change the value of H value according to the real product. The value of springback increases with the increase of H value in the beginning. After ratio of H/W increases to 0.6, the value of springback fluctuates with the increase of H value. When ratio of H/W is about 0.5, the springback values are mostly less than ± 0.5 mm in key sections, which is acceptable.

Strength Analysis for Composite Windshield of Commercial Aircraft

2014 ◽  
Vol 1030-1032 ◽  
pp. 1010-1013
Author(s):  
Ya Xiong Du ◽  
Shu Li ◽  
Kai Guo
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Rational Design ◽  
Element Model ◽  
Strength Analysis ◽  
Commercial Aircraft ◽  
Load Pressure ◽  
Full Size ◽  
Advanced Composites ◽  
The Finite Element Model

With the development of advanced composites technology, composites instead of traditional aluminum alloy, will be widely used to build full-size aircraft windshield structure in the aviation field. The finite element model of commercial aircraft composite windshield is established in the environment of Msc.Patran / Nastran. And based on Tasi-Wu failure criterion, the strength of windshield structure under typical load pressure is predicted and analyzed during failure processes. It shows that composite windshield can work better through rational design according to the analysis result.

scholarly journals Soldering of 7075 Aluminum Alloy Using Ni-P and Cu-Cr Electrodeposited Interlayers

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4100
Author(s):  
Zbigniew Mirski ◽  
Ireneusz Ciepacz ◽  
Tomasz Wojdat
Keyword(s):  
Electron Microscopy ◽  
Shear Strength ◽  
Aluminum Alloy ◽  
Light And Electron Microscopy ◽  
7075 Aluminum Alloy ◽  
7075 Alloy ◽  
Aluminum Alloy 7075 ◽  
Soldered Joint ◽  
Measured Hardness ◽  
Made In

Direct soldering of the aluminum alloy 7075 is very difficult or even impossible. In order to make it possible, galvanic coatings and the procedures for their application on alloy surfaces were developed. The paper presents structures and mechanical properties of soldered joints of the 7075 alloy, made in indirect way with use of electrolytically deposited Ni-P and Cu-Cr coatings. Application of the newly developed Ni-P and Cu-Cr coatings on base surfaces of the 7075 alloy is described. The results of wettability examination of the S-Sn97Cu3 solder in the droplet test and by spreading on the coatings applied on the 7075 substrates are presented. The wettability angle of both coatings was lower than 30°. The results of metallographic examinations with use of light and electron microscopy are presented. It was shown that adhesion of metallic coatings to the aluminum alloy is good, exceeding shear strength of the S-Sn97Cu3 solder. Shear strength of soldered joint was equal to 35 ± 3 MPa. Measured hardness of the Ni-P interlayer reached high value of 471 HV 0.025.

scholarly journals Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Metals ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 31 ◽  
Author(s):  
Anheng Wang ◽  
Hongqian Xue ◽  
Emin Bayraktar ◽  
Yanli Yang ◽  
Shah Saud ◽  
...  
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Element Model ◽  
Effective Control ◽  
Curvature Radius ◽  
3D Fem ◽  
Fe Method ◽  
Element Analysis ◽  
Roll Bending ◽  
Bending Process

This paper focuses on the twist defects and the control strategy in the process of four-roll bending for aluminum alloy Z-section profiles with large cross-section. A 3D finite element model (3D-FEM) of roll bending process has been developed, on the premise of the curvature radius of the profile, the particularly pronounced twist defects characteristic of 7075-O aluminum alloy Z-section profiles were studied by FE method. The simulation results showed that the effective control of the twist defects of the profile could be realized by adjusting the side roller so that the exit guide roll was higher than the entrance one (the side rolls presented an asymmetric loading mode with respect to the main rolls) and increasing the radius of upper roll. Corresponding experimental tests were carried out to verify the accuracy of the numerical analysis. The experimental results indicated that control strategies based on finite element analysis (FEA) had a significant inhibitory function on twist defects in the actual roll bending process.

Research on Thread Forming Process of Extrusion Tapping of Internal Thread

2011 ◽  
Vol 80-81 ◽  
pp. 631-637
Author(s):  
Yong Yi Li ◽  
Sheng Dun Zhao
Keyword(s):  
Element Model ◽  
Processing Method ◽  
Internal Thread ◽  
Extrusion Force ◽  
Forming Process ◽  
Forming Simulation ◽  
Important Processing ◽  
Simplified Finite Element Model ◽  
Deformation Area ◽  
Area And Volume

Extrusion tapping is a novel and important processing method of internal thread, carrying out research on the thread forming process can contribute to a better application of this process in more industrial situation. The principle of extrusion tapping of internal thread is introduced in this paper firstly, and then the simplified finite element model of extrusion tapping and the thread forming simulation is conducted. Next, the thread forming process and metal plastic flow law during extrusion tapping of internal thread are analyzed based on the simulation. Finally, the revised formulas for calculating extrusion deformation area and volume are presented and comparison are made with the referenced formulas, the results show that the revised formulas can express the practical extrusion deformation area and volume more correctly. Furthermore, the similar law between the revised extrusion deformation volume and extrusion force obtained from simulation are proved effectively.

Turning Thermal Deformation Analysis of Aluminum Alloy Spherical Plain Bearing Outer Ring

2014 ◽  
Vol 556-562 ◽  
pp. 733-737
Author(s):  
Yan Jun Li ◽  
Bao Fu Li
Keyword(s):  
Aluminum Alloy ◽  
Element Model ◽  
Outer Ring ◽  
Deformation Analysis ◽  
Machining Accuracy ◽  
Plain Bearing ◽  
Axial Deformation ◽  
Machining Error ◽  
Deformation Law ◽  
Spherical Plain Bearing

Against the problem of large machining error and low productivity of aluminum alloy spherical plain bearing, the paper is concentrated on building finite element model in MATLAB to research the radial and axial deformation law under various cutting conditions with theories of heat transfer, isoparametric element and functional variational method, providing theoretical and data support to enhance machining accuracy of spherical plain bearing outer ring.

Finite Element Analysis for Comprehensive Residual Stress of 7075 Aluminum Alloy Thick Plate

2010 ◽  
Vol 154-155 ◽  
pp. 1255-1261
Author(s):  
Hai Yan Li ◽  
Yi Du Zhang ◽  
Hong Wei Zhang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Thick Plate ◽  
Coupling Effect ◽  
Element Model ◽  
Forming Process ◽  
Element Analysis ◽  
Field Coupling ◽  
Simulation And Experiment

Based on “physical field coupling” finite element method, the generation of residual stress and interactive coupling effect were analyzed during the forming process of aluminum alloy thick-plate. Therefore, comprehensive residual stress generated from rolling, quenching and stretching was obtained. The finite element model was proved effective by comparing the results of simulation and experiment. Results show that percent reduction has significant influence to the distribution and magnitude of rolling stress; There is a coupling effect between rolling stress and quenching stress, which represents a basic state; Furthermore, after stretching the distribution of coupling stress remains, but the value reduces greatly; The residual stress has got the minimum, when stretching is near 3%.

scholarly journals Cost based optimization of industrial bulk CNG filling facility operations

2020 ◽  
pp. 206-206
Author(s):  
Ismail Cetiner ◽  
Ahmet Coskun
Keyword(s):  
Natural Gas ◽  
Fossil Fuels ◽  
Real Data ◽  
Plant Management ◽  
World Population ◽  
Filling Process ◽  
Filling Rate ◽  
Factors Affecting ◽  
Optimum Cost ◽  
Made In

In line with the increase in the world population, natural gas, which has an increasing share in fossil fuels, is nowadays transported throughout pipelines in the form of liquefied natural gas (LNG) and compressed natural gas (CNG). Natural gas is preferred to be transported with CNG in terms of optimum cost. CNG is reduced to a volume of 1/250 at 200 bar pressure in filling facilities and is transported to multi-element gas containers or gas tankers where pipelines do not reach. Although the highest cost for these plants seems to be gas transportation costs, the design, infrastructure and operational gaps, especially in plant management of the filling facilities constitute the costs that are not significantly visible. In parallel with the costs incurred, in this study, a pre-cooling process was actively applied for cost-based improvement in a bulk CNG filling facility, while operational optimization was aimed passively. The filling process of the facility in 2016 was examined according to real data and pre-cooling was made in 2017 by adding a ?chiller? to the filling process to increase the filling rate to tankers. Thanks to the precooling in 2017, the filling amount made to tankers increased by %7.23. In 2018, the filling process was analyzed in detail according to the data of 2017 and the factors affecting the filling rate were determined. According to these factors, the filling operation has been optimized on a cost basis. Filling operations in 2018 have been optimized for factors varying from month to month and even day, such as; temperature conditions, filling method, the structure of gas tankers and filling platforms, ie the effect of the material used, personnel effect and the filling rate of machines like chiller, compressor. After optimization, the amount of filling made in 2018 increased by %4.36 compared to 2017.

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