Finite Element Analysis of Damage Evolution of Micro-Holes in Complex Shape of Automotive Casting Aluminum Alloy

The creep deformation and damage evolution of nickel base superalloy (Waspaloy) at 700 °C are studied using the classic Kachanov–Rabotnov (KR) and a recently developed Sin-hyperbolic (Sinh) model. Uniaxial creep deformation and Bridgman rupture data collected from literature are used to determine the model constants and to compare the KR and the Sinh solutions. Finite-element (FE) simulations on a single eight-node element are conducted to validate the accuracy of the FE code. It is observed that KR cannot predict the creep deformation, damage, and rupture life of nickel base superalloys accurately using one set of constants for all the stress levels. The Sinh model exhibits a superior ability to predict the creep behavior using one set of constants for all the stress levels. Finite-element analysis (FEA) on 3D Bridgman notched Waspaloy specimen using the Sinh model is conducted. The results show that the Sinh model when combined with a representative stress equation and calibrated with experimental data can accurately predict the “notch effect” observed in the rupture life of notched specimen. Contour plots of damage evolution and stress redistribution are presented. It is demonstrated that the Sinh model is less stress sensitive, produces unconditional critical damage equal to unity at rupture, exhibits a more realistic damage distribution around the crack tip, and offers better crack growth analysis than KR.

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Forging Process Analysis of 6061 Aluminum Alloy Motorcycle Brake Parts

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.901.176 ◽

2021 ◽

Vol 901 ◽

pp. 176-181

Author(s):

Tung Sheng Yang ◽

Chieh Chang ◽

Ting Fu Zhang

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Aluminum Alloy ◽

Metal Forming ◽

Process Analysis ◽

Surface Hardness ◽

Dimensional Accuracy ◽

Die Design ◽

Element Analysis ◽

Forging Process

This paper used finite element analysis of metal forming to study the forging process and die design of aluminum alloy brake parts. According to the process parameters and die design, the brake parts were forged by experiment. First, the die design is based on the product size and considering parting line, draft angle, forging tolerance, shrinkage and scrap. Secondly, the finite element analysis of metal forming is used to simulate the forging process of aluminum alloy brake parts. Finally, the aluminum alloy brake levers with dimensional accuracy and surface hardness were forged.

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A FINITE ELEMENT ANALYSIS OF BURR FORMATION IN FACE MILLING OF A CAST ALUMINUM ALLOY

Machining Science and Technology ◽

10.1080/10910340701339895 ◽

2007 ◽

Vol 11 (2) ◽

pp. 157-181 ◽

Cited By ~ 12

Author(s):

Partchapol Sartkulvanich ◽

Hakan Sahlan ◽

Taylan Altan

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Aluminum Alloy ◽

Face Milling ◽

Burr Formation ◽

Cast Aluminum Alloy ◽

Cast Aluminum ◽

Element Analysis

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Finite element analysis of deep drawing

Advances in Mechanical Engineering ◽

10.1177/1687814019874561 ◽

2019 ◽

Vol 11 (9) ◽

pp. 168781401987456 ◽

Cited By ~ 1

Author(s):

Dyi-Cheng Chen ◽

Li Cheng-Yu ◽

Yu-Yu Lai

Keyword(s):

Finite Element Analysis ◽

Plastic Deformation ◽

Finite Element ◽

Aluminum Alloy ◽

Deep Drawing ◽

Drawing Ratio ◽

Element Analysis ◽

Forming Mechanism ◽

Analysis Process ◽

Plastic Flow Stress

With the advancement of technology, aiming for achieving a greater lightness and smaller size of 3C products, parts processing technology not only needs to explore the basic scientific theory of materials but also needs to discuss the process of deep drawing numerical and the plastic deformation. This study is based on the square shape of the deep drawing numerical simulation, and aluminum alloy plastic flow stress was input into the finite element method for simulation of plastic deformation in the aluminum alloy friction, mold clamping force, and frequency, as well as amplitude in the influence of forming mechanism and the drawing ratio of aluminum alloy. Finite element analysis software has the function of grid automatic rebuild, which can rebuild the broken grid in the analysis into a complete grid shape, which can avoid the divergence caused by numerical calculation in the analysis process. The greater the obtained error value, the best plastic parameters can be found.

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