scholarly journals Modelling of thermally supported clinching of fibre-reinforced thermoplastics: Approaches on mesoscale considering large deformations and fibre failure

2021 ◽  
Author(s):  
Benjamin Gröger ◽  
Andreas Hornig ◽  
Arne Hoog ◽  
Maik Gude
Keyword(s):  
Numerical Simulation ◽  
Large Deformations ◽  
Dissimilar Materials ◽  
Single Step ◽  
Arbitrary Lagrangian Eulerian ◽  
Fibre Failure ◽  
Feasibility Robustness ◽  
Contact Models ◽  
Reinforced Thermoplastics ◽  
Joining Process

Thermally supported clinching (Hotclinch) is a novel promising process to join dissimilar materials. Here, metal and fibre-reinforced thermoplastics (FRTP) are used within this single step joining process and without the usage of auxiliary parts like screws or rivets. For this purpose, heat is applied to improve the formability of the reinforced thermoplastic. This enables joining of the materials using conventional clinching-tools. Focus of this work is the modelling on mesoscopic scale for the numerical simulation of this process. The FTRP-model takes the material behaviour both of matrix and the fabric reinforced organo-sheet under process temperatures into account. For describing the experimentally observed phenomena such as large deformations, fibre failure and the interactions between matrix and fibres as well as between fibres themselves, the usage of conventional, purely Lagrangian based FEM methods is limited. Therefore, the combination of contact-models with advanced modelling approaches like Arbitrary-Lagrangian-Eulerian (ALE), Coupled-Eulerian-Lagrangian (CEL) and Smooth-ParticleHydrodynamics (SPH) for the numerical simulation of the clinching process are employed. The different approaches are compared with regard to simulation feasibility, robustness and results accuracy. It is shown, that the CEL approach represents the most promising approach to describe the clinching process.

Numerical Simulation of Premixed Propane/Air Flame Propagation Using a Dynamically Thickened Flame Approach

2013 ◽  
Vol 444-445 ◽  
pp. 1574-1578 ◽  
Author(s):  
Hua Hua Xiao ◽  
Zhan Li Mao ◽  
Wei Guang An ◽  
Qing Song Wang ◽  
Jin Hua Sun
Keyword(s):  
Numerical Simulation ◽  
Flame Propagation ◽  
Numerical Study ◽  
Vortex Motion ◽  
Combustion Process ◽  
Single Step ◽  
Premixed Combustion ◽  
Premixed Flame ◽  
Flame Surface ◽  
Arrhenius Kinetics

A numerical study of premixed propane/air flame propagation in a closed duct is presented. A dynamically thickened flame (TF) method is applied to model the premixed combustion. The reaction of propane in air is taken into account using a single-step global Arrhenius kinetics. It is shown that the premixed flame undergoes four stages of dynamics in the propagation. The formation of tulip flame phenomenon is observed. The pressure during the combustion process grows exponentially at the finger-shape flame stage and then slows down until the formation of tulip shape. After tulip formation the pressure increases quickly again with the increase of the flame surface area. The vortex motion behind the flame front advects the flame into tulip shape. The study indicates that the TF model is quite reliable for the investigation of premixed propane/air flame propagation.

Continuous Roll Forming Simulation Using Arbitrary Lagrangian Eulerian Formalism

2011 ◽  
Vol 473 ◽  
pp. 564-571 ◽  
Author(s):  
Romain Boman ◽  
Jean Philippe Ponthot
Keyword(s):  
Numerical Simulation ◽  
Rolling Direction ◽  
Initial Guess ◽  
Roll Forming ◽  
Arbitrary Lagrangian Eulerian ◽  
The Finite Element Method ◽  
Forming Simulation ◽  
Element Size ◽  
Cold Roll ◽  
Classical Lagrangian

Due to the length of the mill, accurate modelling of stationary solution of continuous cold roll forming by the finite element method using the classical Lagrangian formulation usually requires a very large mesh leading to huge CPU times. In order to model industrial forming lines including many tools in a reasonable time, the sheet has to be shortened or the element size has to be increased leading to inaccurate results. On top of this, applying loads and boundary conditions on this smaller sheet is usually more difficult than in the continuous case. Moreover, transient dynamic vibrations, which are unnecessarily computed, may appear when the sheet hits each tool, decreasing the convergence rate of the numerical simulation. Beside this classical Lagrangian approach, an alternative method is given by the Arbitrary Lagrangian Eulerian (ALE) formalism which consists in decoupling the motion of the material and the mesh. Starting from an initial guess of the sheet geometry between the rolls, the numerical simulation is performed until the stationary state is reached with a mesh, the nodes of which are fixed in the rolling direction but are free to move on perpendicular plane, following the geometrical boundary of the sheet. The whole forming line can then be modelled using a limited number of brick and contact elements because the mesh is only refined near the tools where bending and contact occur. In this paper, ALE results are compared to previous Lagrangian simulations and experimental measurement on a U-channel, including springback. Advantages of the ALE method are finally demonstrated by the simulation of a tubular rocker panel on a 16-stands forming mill.

Process-Integrated Projection Welding during Deep Drawing

2016 ◽  
Vol 1140 ◽  
pp. 59-66 ◽  
Author(s):  
Masood Jalanesh ◽  
Andre Miller ◽  
Marco Hehmann ◽  
André Spiekermeier ◽  
Sven Hübner ◽  
...  
Keyword(s):  
Deep Drawing ◽  
Active Surface ◽  
Single Step ◽  
Downstream Process ◽  
Process Step ◽  
Projection Welding ◽  
Process Chains ◽  
Innovative Tool ◽  
Edge Based ◽  
Joining Process

Within deep drawing processes, welding represents an innovative approach to optimising the branched process chains which entail uneconomic process steps in production and transport lines. Previous applications of thermal joining processes in presses required a downstream process step for joining standardised functional elements such as nuts. Within the scope of this publication, a weldable tool system is presented which offers the possibility of welding a deep drawing component to an automatically added non-standardised holder in a single-step deep drawing process without additional dwell time in the bottom dead point. In order to realise this innovative tool system, the interdependencies of deep drawing and projection welding are considered to enable a splash-free welding on flat and curved component areas, such as the rounding of a punch edge. Based on experimental research a special concept for the tool kinematics of welding electronics is drawn up which is based on press kinematics. In addition, this article also deals with electric insulation and the forming forces which have an impact on the welding electrodes integrated into the active surface of the forming tool. Thus, the joining process becomes independent from the type of press.

Investigation of the Stability of Axially Moving Beams With Discrete Masses

2021 ◽  
Author(s):  
Konstantina Ntarladima ◽  
Michael Pieber ◽  
Johannes Gerstmayr
Keyword(s):  
Large Deformations ◽  
Equations Of Motion ◽  
Arbitrary Lagrangian Eulerian ◽  
Axial Motion ◽  
Multibody Modeling ◽  
Conveyor Belts ◽  
Axially Moving Beams ◽  
Concentrated Masses ◽  
Axially Moving ◽  
The Stability

Abstract The present paper addresses axially moving beams with co-moving concentrated masses while undergoing large deformations. For the numerical modeling, a novel beam finite element is introduced, which is based on the absolute nodal coordinate formulation extended with an additional Eulerian coordinate to represent the axial motion. The resulting formulation is well known as Arbitrary Lagrangian Eulerian (ALE) method, which is often used for axially moving beams and pipes conveying fluids. As compared to previous formulations, the present formulation allows us to introduce the Eulerian part by an independent coordinate, which fully incorporates the dynamics of the axial motion, while the shape functions remain independent of the beam coordinates and are thus constant. The proposed approach, which is derived from an extended version of Lagrange’s equations of motion, allows for the investigation of the stability of axially moving beams for a certain axial velocity and stationary state of large deformation. A multibody modeling approach allows us to extend the beam formulation for co-moving discrete masses, which represent concentrated masses attached to the beam, e.g., gondolas in ropeway systems, or transported masses in conveyor belts. Within numerical investigations we show that a larger number of discrete masses behaves similarly as the case of (continuously) distributed mass along the beam.

Joining sheets made from dissimilar materials by hole hemming

2022 ◽  
pp. 146442072110726
Author(s):  
Mohammad Mehdi Kasaei ◽  
Lucas FM da Silva
Keyword(s):  
Mechanical Properties ◽  
Research Work ◽  
Dissimilar Materials ◽  
Element Analysis ◽  
Lightweight Structures ◽  
Lap Shear ◽  
Gradual Failure ◽  
Peel Tests ◽  
Dp780 Steel ◽  
Joining Process

This research work presents a new joining process based on the hemming process for attaching sheets made from dissimilar materials with very different mechanical properties. The process is termed ‘hole hemming’ and consists in producing a mechanical interlock between pre-drilled holes which can be made anywhere on the sheets. The process is carried out in a two-stage operation including flanging the hole of an outer sheet and bending the flange over the hole of an inner sheet. First, the joining stages and the required tools are designed. Then, the joining of DP780 steel and AA6061-T6 aluminium alloy sheets, which are applied to manufacture lightweight structures in the automotive industries, is investigated using finite element analysis. Results show that the hole hemming process is able to successfully join these materials without fracture. The hole-hemmed joint withstood the maximum forces of 2.5 and 0.5 kN in single-lap shear and peel tests, respectively, and failed with hole bearing mode which is known as a gradual failure mode. The results demonstrate the applicability of the hole hemming process for joining dissimilar materials.

Assumed Multivariate Beta-PDF Modeling for Turbulent Nonpremixed Flames

2007 ◽  
Author(s):  
Susumu Noda ◽  
Kunihiko Yamamuro ◽  
Yuzuru Nada ◽  
Masato Fujisaka
Keyword(s):  
Numerical Simulation ◽  
Reaction Mechanism ◽  
Moment Method ◽  
Mass Fraction ◽  
Reaction Rate ◽  
Single Step ◽  
Present Approach ◽  
Nonpremixed Flames ◽  
Good Prediction ◽  
Irreversible Reaction

Numerical simulation based on a moment method is conducted to investigate the feasibility of an assumed probability density function (PDF) approach in the configuration of a turbulent jet nonpremixed flame. In this study, a multivariate β-PDF is employed to account for turbulence-chemistry interaction. The multivariate β-PDF approach has an advantage that only one additional transport equation of sum of composition variances is solved to determine the shape of species PDF to transport equations of mean compositions. The numerical simulation is carried out for H3 flame. Reaction mechanism is a single-step irreversible reaction including H2, O2 and H2O species. The results are compared with those from measurements and a combined PDF/moment method that detailed reaction mechanism is applied. Velocity distributions obtained by the multivariate β-PDF approach show good agreement with measurements and combined PDF/moment results, which indicates that the present approach can predict the flow pattern of nonpremixed flames. The present approach also provides good predictions in terms of mean temperature and mass fraction. PDFs of mass fraction obtained by the present approach are similar to those by the combined PDF/moment method. On the other hand, the variance of temperature is underpredicted, which is attributed to an approximation of temperature variance. In order to achieve a good prediction of the reaction rate, a PDF approximation of enthalpy is proposed for the evaluation of mean reaction rate.

Numerical Simulation for Free Turbulent Reacting Flow by Particle Method

2003 ◽  
Author(s):  
Tomomi Uchiyama ◽  
Naohiro Otsuki
Keyword(s):  
Numerical Simulation ◽  
Chemical Reaction ◽  
Mixing Layer ◽  
Particle Method ◽  
Reacting Flows ◽  
Single Step ◽  
Reacting Flow ◽  
Turbulent Reacting Flows ◽  
Plane Mixing Layer ◽  
Irreversible Chemical Reaction

This paper presents a particle method for free turbulent reacting flows. The vorticity and concentration fields are discretized into the vortex and concentration elements, respectively, and the behavior of the elements is calculated with the Lagrangian method. The chemical reaction is estimated through the Lagrangian calculation for the strength of concentration element. The particle method is applied to simulate a plane mixing layer with a single-step and irreversible chemical reaction of non-premixed reactants so as to discuss the applicability.

Validation of an Improved Contact Method for Multi-Material Eulerian Hydrocodes in Three-Dimensions

2019 ◽  
Author(s):  
Kenneth C. Walls ◽  
David L. Littlefield
Keyword(s):  
Finite Element ◽  
Large Deformations ◽  
Three Dimensions ◽  
Contact Method ◽  
Arbitrary Lagrangian Eulerian ◽  
Aspect Ratios ◽  
Ale Methods ◽  
Lagrangian Finite Element ◽  
Multiple Materials ◽  
Natural Description

Abstract Realistic and accurate modeling of contact for problems involving large deformations and severe distortions presents a host of computational challenges. Due to their natural description of surfaces, Lagrangian finite element methods are traditionally used for problems involving sliding contact. However, problems such as those involving ballistic penetrations, blast-structure interactions, and vehicular crash dynamics, can result in elements developing large aspect ratios, twisting, or even inverting. For this reason, Eulerian, and by extension Arbitrary Lagrangian-Eulerian (ALE), methods have become popular. However, additional complexities arise when these methods permit multiple materials to occupy a single finite element.

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