scholarly journals New Manufacturing Process and Product Developments in Metal Forming Industry Using Finite Element Modelling and Optimization Techniques

2021 ◽  
Author(s):  
Van Bac Nguyen ◽  
Martin English
Keyword(s):  
Finite Element ◽  
Numerical Modelling ◽  
Manufacturing Process ◽  
Finite Element Modelling ◽  
Optimization Techniques ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Element Modelling ◽  
Cold Roll ◽  
Modelling And Optimization

The objective of this paper is to outline a practical approach using numerical modelling and optimization techniques for process and product developments in metal cold rolled forming industry. The optimum economic viability in manufacturing industry requires a minimization of the amount of material used while the structural performance of a cold roll formed product relies on maintaining the stiffness and strength of the section in applications. This leads to the development of new cold forming processes and alternative cold roll formed profiles searching for the optimal profile. In this paper, a Finite Element modelling approach was utilized to simulating complicated manufacturing process and products and optimization techniques including Design Of Experiments was used to optimize the shape design of the end products to obtain lighter products while maintaining the product strength. These developments were illustrated through two case studies of Hadley Industries plc which included (1) numerical modelling of a novel Ultra STEEL® cold roll forming process, and (2) optimization of cold roll forming sections.

418 Cold roll forming process of wrought magnesium alloy using finite element analysis

2014 ◽  
Vol 2014.22 (0) ◽  
pp. 163-164
Author(s):  
Shintaro AKANUMA ◽  
Tomoya SUZUKI ◽  
Hayato ASO ◽  
Bunkyo KYO ◽  
Shinichi NISHIDA ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Magnesium Alloy ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Roll ◽  
Wrought Magnesium Alloy ◽  
Roll Forming Process

scholarly journals Dimpling process in cold roll metal forming by finite element modelling and experimental validation

2014 ◽  
Vol 16 (3) ◽  
pp. 363-372 ◽  
Author(s):  
V.B. Nguyen ◽  
C.J. Wang ◽  
D.J. Mynors ◽  
M.A. English ◽  
M.A. Castellucci
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Finite Element Modelling ◽  
Experimental Validation ◽  
Element Modelling ◽  
Cold Roll

A 3D Finite Element Simulation of Cold Roll Forming of Wrought Magnesium Alloy Sheets

2013 ◽  
Vol 459 ◽  
pp. 455-461 ◽  
Author(s):  
Hisaki Watari ◽  
Hidemitsu Hamano ◽  
Shi Ichi Nishida ◽  
Hayato Asou
Keyword(s):  
Finite Element ◽  
Magnesium Alloy ◽  
Alloy Sheet ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Major Barrier ◽  
Magnesium Alloy Sheet ◽  
Cold Roll ◽  
Wrought Magnesium Alloy ◽  
Forming Characteristics

In recent several years, although production of magnesium has risen dramatically, production of magnesium alloy sheet remains still at a very low level in practical use. The major barrier to greatly increased magnesium alloy use has been in still primarily high manufacturing cost as well as poor work ability of wrought magnesium sheet alloys. One of the author has investigated in cold roll forming of magnesium alloy, however detailed forming characteristics of the wrought magnesium alloy sheets has not been clarified. The aim of the study is to confirm possibilities of practical use of wrought magnesium alloy by using told roll forming process. A three dimensional elasto-plastic analysis by finite element method (FEM) has been conducted to examine the shapes of cross section, spring back characteristics, bending strains and longitudinal membrane strain of magnesium alloy sheet and cold rolled steel sheet during forming.

scholarly journals Finite Element Modelling of Wire-arc-additive-manufacturing Process

Procedia CIRP ◽  
2016 ◽  
Vol 55 ◽  
pp. 109-114 ◽  
Author(s):  
Filippo Montevecchi ◽  
Giuseppe Venturini ◽  
Antonio Scippa ◽  
Gianni Campatelli
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Finite Element Modelling ◽  
Element Modelling ◽  
Wire Arc Additive Manufacturing

scholarly journals Finite element modelling and optimization of Ge/SiGe superlattice based thermoelectric generators

2021 ◽  
Vol 3 (2) ◽  
Author(s):  
Ameze Big-Alabo
Keyword(s):  
Finite Element ◽  
Finite Element Modelling ◽  
Output Voltage ◽  
Methodological Approach ◽  
Operating Conditions ◽  
Thermoelectric Generators ◽  
Voltage Distribution ◽  
Governing Equations ◽  
Element Modelling ◽  
Modelling And Optimization

AbstractThe study presents the development of a 3D Finite Element modelling (FEM) technique for a uni-coupled Ge/SiGe superlattice-based module configuration. The methodological approach involved the development of the geometrical design of the Ge/SiGe – based Thermoelectric generator (TEG), defining the thermoelectric material properties and boundary conditions and then implementation of the governing equations to obtain an approximate solution via meshing of the TEG module. The developed FEM was then used to optimize the geometry of the TEG with the aim of reducing the contact resistance for improved performances. One way to achieve this is to reduce the thickness of the silicon substrate. Thus by reducing the thickness of the substrate, the thermal losses in the system will be minimized. Secondly, by increasing the superlattice heights, the output voltage also increased and given the anisotropic nature of the superlattice, it was inferred that the optimal voltage measurements can be obtained at the surface of the superlattice which yields the maximum leg height. The relevance of this study is that the FEM allows the simulation of the TEG module for different real-world conditions that would otherwise be expensive and time-consuming to investigate experimentally. It also gives insight to the temperature and voltage distribution of the TEG module under varying operating conditions.

scholarly journals Experimental and numerical investigation of the effect of holes on the springback in cold roll forming of UHSS

2021 ◽  
Author(s):  
Zhi-min Liu ◽  
Pan Zhang ◽  
xiaoli liu ◽  
ming zhang ◽  
qiang ma ◽  
...  
Keyword(s):  
Finite Element ◽  
Elastic Modulus ◽  
Finite Element Model ◽  
High Strength ◽  
Element Model ◽  
Tensile Tests ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
Cold Roll ◽  
Forming Precision

Abstract Ultra-high strength steel (UHSS) pre-notched sections are getting growing popularity in the automotive industry with the development of automotive lightweight. However, the springback of UHSS products is large, and the existence of holes also has an effect on the springback. Accurate prediction of springback of UHSS pre-notched products in cold roll forming ( CRF ) is a key issue to be solved. In this paper, the effect of holes on the springback of UHSS in CRF is discussed by simulation and experiment. The finite element model of pre-notched car threshold was constructed, and its accuracy was validated by continuous CRF experiment. The mathematical model of variable elastic modulus determined by tensile tests of martensite (MS) 1300 was applied in finite element model. The accuracy of springback was improved by 15% in the hole region by using variable elastic modulus . Several forming schemes were designed to research the effect of different features on the springback in the hole region. The results show that the existence of holes reduces the springback and the effect is different at different positions of the car threshold. The springback in the hole region decreases with the increase of the number of stands, the strip thickness and the hole diameter, and with the decrease of the distance between stands and the distance between holes. This study provides a help for reducing the influence of holes on the springback and improving the forming precision of pre-notched sections in the actual production of CRF.

Sign in / Sign up

Export Citation Format

Share Document