Finite element simulations of the doublediaphragm forming process

Multi-Roll Stretch forming process is a new flexible process which is used for forming hyperbolic-degree surface pieces. Using the Multi-point flexible floating clamping system, the metal sheet can be more easily formed, and the flexibility can be much higher, which the ordinary floating clamping cannot have. A series of finite element simulations and experiments have been done for the process of forming saddle-shaped parts using Multi-Point flexible floating clamping system, and ordinary floating clamping system. The results show that the quality of the part formed using flexible floating clamping system is better.

Download Full-text

Piecewise Fifth Order Spline Interpolation for Line Heating Forming Process

Volume 2: Advanced Manufacturing ◽

10.1115/imece2016-67296 ◽

2016 ◽

Author(s):

Henri Champliaud ◽

Zhengkun Feng ◽

David Provencher ◽

Danick Tousignant ◽

Javad Gholipour

Keyword(s):

Finite Element ◽

Flat Plate ◽

Spline Interpolation ◽

Finite Element Simulations ◽

Thermal Gradients ◽

Interpolation Model ◽

Forming Process ◽

Line Heating ◽

Order Spline ◽

Fifth Order

A fifth order piecewise spline interpolation model has been developed for computing the evolving geometry of a plate deformed by line heating thermal gradients. 3D formulations are presented and applied to continuously derivable geometries to demonstrate the capability of the methodology. Then the developed formulation is used to form gradually, with a sequence of heating lines, a 3D shape from an initially flat plate. The geometric results obtained from finite element simulations with three heating lines are used to illustrate where heating lines should be applied on a flat plate to achieve the intended geometry of a workpiece. Furthermore, it is shown that applying the developed piecewise fifth order spline interpolation model to the same flat plate produces results very close to the ones obtained from the thermal structural FE simulations.

Download Full-text

Study of Multi-Roll Stretch Forming Process Using Different Clamps

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.44-47.2752 ◽

2010 ◽

Vol 44-47 ◽

pp. 2752-2756 ◽

Cited By ~ 1

Author(s):

Hao Han Zhang ◽

Ming Zhe Li ◽

Wen Zhi Fu ◽

Zhi Qing Hu

Keyword(s):

Finite Element ◽

Sheet Metal ◽

Opposite Direction ◽

Critical Value ◽

Finite Element Simulations ◽

Stretch Forming ◽

Forming Process ◽

Wave Type ◽

Tooth Type ◽

Formed Part

Multi-Roll Stretch Forming process is a new flexible process which is used in forming hyperbolic-degree surface pieces. A series of finite element simulations and experiments have done for the process of forming saddle-shaped parts using two kinds of clamps named Tooth-type clamp and Wave-type clamp. The results show that Wave-type clamp can control the stretching force at an appropriate value. When the stretching force exceeds a critical value, the sheet metal can flow to the opposite direction of Stretch Forming as to maintain that stretching force. The formed part using Wave-type clamp has a better quality than the parts formed using Tooth-type clamp.

Download Full-text

Electromagnetic Sheet Bulging: Analysis of Process Parameters by FE Simulations

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.554-557.741 ◽

2013 ◽

Vol 554-557 ◽

pp. 741-748 ◽

Cited By ~ 5

Author(s):

Joao Pedro M. Correia ◽

Saïd Ahzi

Keyword(s):

Finite Element ◽

Process Parameters ◽

High Speed ◽

Finite Element Simulations ◽

Electromagnetic Forming ◽

Forming Process ◽

High Speed Forming ◽

Bulging Test ◽

High Repeatability

Electromagnetic forming is a non-conventional forming process and is classified as a high-speed forming process. It provides certain advantages as compared to conventional forming processes: improved formability, high repeatability and productivity, reduction in tooling cost and reduction of springback and of wrinkling. However, various process parameters affect the performance of the electromagnetic forming system. Finite element simulations are very useful to optimize a process because they can reduce time and costs. With the aim of investigating the effects of the process parameters on the deformed blank geometry, finite element simulations of an electromagnetic sheet bulging test have been performed in this work. Furthermore the role of first impulse of discharged current is also investigated.

Download Full-text

Process modeling and optimization of the staggered backward flow forming process of maraging steel via finite element simulations

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-016-8559-7 ◽

2016 ◽

Vol 87 (5-8) ◽

pp. 1851-1864 ◽

Cited By ~ 14

Author(s):

Hemant Shinde ◽

Pushkar Mahajan ◽

Abhishek Kumar Singh ◽

Ramesh Singh ◽

K. Narasimhan

Keyword(s):

Finite Element ◽

Maraging Steel ◽

Process Modeling ◽

Finite Element Simulations ◽

Forming Process ◽

Flow Forming ◽

Modeling And Optimization ◽

Backward Flow Forming

Download Full-text

Effect of Residual Forming Stresses on Fracture in ERW Pipe

Volume 3: Operations, Monitoring and Maintenance; Materials and Joining ◽

10.1115/ipc2016-64553 ◽

2016 ◽

Author(s):

Ted L. Anderson ◽

Gregory W. Brown

Keyword(s):

Heat Treatment ◽

Residual Stress ◽

Finite Element ◽

Residual Stresses ◽

Fracture Behavior ◽

Finite Element Simulations ◽

Finite Element Analyses ◽

Forming Process ◽

Cold Expansion ◽

The Past

Many older pipelines contain significant residual stress due to the forming process. Cold expansion or a normalizing heat treatment can virtually eliminate residual forming stresses, but these practices were less common in the past. In the absence of cold expansion or normalization, residual forming stresses can be reduced by hydrostatic testing or operating pressures, but not eliminated entirely. Residual stresses can contribute to fracture in pipelines, particularly when the material toughness is low. This article presents a series of analyses that seek to quantify the magnitude of residual forming stresses as well as their impact on pipeline integrity. The pipe forming process was simulated with elastic-plastic finite element analyses, which considered the effect of subsequent loading on relaxation of residual stresses. A second set of finite element simulations were used to quantify the effect of residual stresses on fracture behavior.

Download Full-text

Finite element simulations and experimental verifications for forming limit curve determination of two-layer aluminum/brass sheets considering the incremental forming process

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211045212 ◽

2021 ◽

pp. 146442072110452

Author(s):

A. Jalali ◽

R. Hashemi ◽

M. Rajabi ◽

P. Tayebi

Keyword(s):

Numerical Simulation ◽

Finite Element ◽

Incremental Forming ◽

Bottom Layer ◽

Finite Element Simulations ◽

Experimental Results ◽

Forming Limit ◽

Forming Process ◽

Simulation Results ◽

Aluminum 1050

In this paper, forming limit diagram (FLD) of aluminum/brass two-layer sheets through an incremental forming process (ISF) was studied numerically and experimentally. At first, the two-layer aluminum 1050/brass (65% copper) sheets were fabricated using the roll bonding process. Also, the finite element simulations of the incremental forming process with ABAQUS software were utilized to predict the FLD. For this purpose, the criterion of the second derivative of the equivalent plastic strain was used to predict fracture. Finally, the numerical simulation results were compared with the experimental results. For instance, comparing experimental and numerical FLD0 values for the formed samples with forming angle 62.5-degree showed a 7% difference. However, the difference was negligible, and numerical simulation results could be used with an appropriate reliability coefficient. The effect of sheet arrangement towards tools was then investigated. It finds out from the experimental results that the formability of the Brass/Al (brass was up layer and aluminum was bottom layer) was more than the Al/Brass (aluminum is up layer and brass is bottom layer). In the following, the ISF parameters such as forming limit angle, step-down, and thickness distribution were investigated.

Download Full-text