scholarly journals A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

2020 ◽  
Vol 8 (10) ◽  
pp. 756
Author(s):  
Ameen Topa ◽  
Burak Can Cerik ◽  
Do Kyun Kim
Keyword(s):  
Numerical Simulations ◽  
Maximum Stress ◽  
Three Dimensional ◽  
Material Model ◽  
Manufacturing Processes ◽  
Arbitrary Lagrangian Eulerian ◽  
Analysis Method ◽  
Seamless Pipe ◽  
Ale Formulation ◽  
Good Agreement

The development of numerical simulations is potentially useful in predicting the most suitable manufacturing processes and ultimately improving product quality. Seamless pipes are manufactured by a rotary piercing process in which round billets (workpiece) are fed between two rolls and pierced by a stationary plug. During this process, the material undergoes severe deformation which renders it impractical to be modelled and analysed with conventional finite element methods. In this paper, three-dimensional numerical simulations of the piercing process are performed with an arbitrary Lagrangian–Eulerian (ALE) formulation in LS-DYNA software. Details about the material model as well as the elements’ formulations are elaborated here, and mesh sensitivity analysis was performed. The results of the numerical simulations are in good agreement with experimental data found in the literature and the validity of the analysis method is confirmed. The effects of varying workpiece velocity, process temperature, and wall thickness on the maximum stress levels of the product material/pipes are investigated by performing simulations of sixty scenarios. Three-dimensional surface plots are generated which can be utilized to predict the maximum stress value at any given combination of the three parameters.

scholarly journals A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

2020 ◽  
Author(s):  
Ameen Topa ◽  
Burak Can Cerik ◽  
Do Kyun Kim
Keyword(s):  
Numerical Simulations ◽  
Maximum Stress ◽  
Three Dimensional ◽  
Material Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Analysis Method ◽  
Seamless Pipe ◽  
Ale Formulation ◽  
Dimensional Surface ◽  
Good Agreement

The development of numerical simulations is potentially useful in predicting the most suitable manufacturing process and ultimately improving product quality. Seamless pipes are manufactured by rotary piercing process in which round bars are fed between two rolls and pierced by a stationary plug. During this process, the material undergoes severe deformation which renders it impractical to be modelled and analysed with conventional finite element methods. In this paper, three dimensional numerical simulations of the piercing process are performed with Arbitrary Lagrangian-Eulerian (ALE) Formulation in LS DYNA software. Details about the material model as well as the elements formulations are elaborated here and mesh sensitivity analysis was performed. The results of the numerical simulations are in good agreement with experimental data found in the literature and the validity of the analysis method is confirmed. The effects of varying workpiece velocity, process temperature, and wall thickness on the maximum stress levels of the product material/pipes are investigated by performing simulations of sixty scenarios. Three dimensional surface plots are generated which can be utilized to predict the maximum stress value at any given combination of the three parameters.

scholarly journals 3D Numerical Simulation of Seamless Pipe Piercing Process by Fluid-Structure Interaction Method

2018 ◽  
Vol 203 ◽  
pp. 06016 ◽  
Author(s):  
Ameen Topa ◽  
Do Kyun Kim ◽  
Youngtae Kim
Keyword(s):  
Numerical Simulations ◽  
Fluid Structure Interaction ◽  
Three Dimensional ◽  
Rolling Process ◽  
Arbitrary Lagrangian Eulerian ◽  
Analysis Method ◽  
Seamless Pipe ◽  
Fluid Structure ◽  
Structure Interaction ◽  
Ale Formulation

Seamless pipes are produced using piercing rolling process in which round bars are fed between two rolls and pierced by stationary plug. During this process, the material undergoes severe deformation which renders it impractical to perform the numerical simulations with conventional finite element methods. In this paper, three dimensional numerical simulations of the piercing process are performed with Fluid-Structure Interaction (FSI) Method using Arbitrary Lagrangian-Eulerian (ALE) Formulation with LS DYNA software. The results of numerical simulations agree with experimental data of Plasticine workpiece and the validity of the analysis method is confirmed.

A Consistent Implementation of Inelastic Material Models into Steady State Rolling

2016 ◽  
Vol 44 (3) ◽  
pp. 174-190 ◽  
Author(s):  
Mario A. Garcia ◽  
Michael Kaliske ◽  
Jin Wang ◽  
Grama Bhashyam
Keyword(s):  
Steady State ◽  
Numerical Simulations ◽  
Viscoelastic Material ◽  
Rolling Contact ◽  
Arbitrary Lagrangian Eulerian ◽  
Ale Formulation ◽  
Inelastic Material ◽  
Material Formulation ◽  
Steady State Rolling ◽  
Efficient Alternative

ABSTRACT Rolling contact is an important aspect in tire design, and reliable numerical simulations are required in order to improve the tire layout, performance, and safety. This includes the consideration of as many significant characteristics of the materials as possible. An example is found in the nonlinear and inelastic properties of the rubber compounds. For numerical simulations of tires, steady state rolling is an efficient alternative to standard transient analyses, and this work makes use of an Arbitrary Lagrangian Eulerian (ALE) formulation for the computation of the inertia contribution. Since the reference configuration is neither attached to the material nor fixed in space, handling history variables of inelastic materials becomes a complex task. A standard viscoelastic material approach is implemented. In the inelastic steady state rolling case, one location in the cross-section depends on all material locations on its circumferential ring. A consistent linearization is formulated taking into account the contribution of all finite elements connected in the hoop direction. As an outcome of this approach, the number of nonzero values in the general stiffness matrix increases, producing a more populated matrix that has to be solved. This implementation is done in the commercial finite element code ANSYS. Numerical results confirm the reliability and capabilities of the linearization for the steady state viscoelastic material formulation. A discussion on the results obtained, important remarks, and an outlook on further research conclude this work.

Vortex rings impinging on walls: axisymmetric and three-dimensional simulations

1993 ◽  
Vol 256 ◽  
pp. 615-646 ◽  
Author(s):  
Paolo Orlandi ◽  
Roberto Verzicco
Keyword(s):  
Numerical Simulations ◽  
Strain Tensor ◽  
Three Dimensional ◽  
Reynolds Numbers ◽  
Vortex Rings ◽  
Compression Phase ◽  
Vortex Pairing ◽  
The Impact ◽  
Good Agreement ◽  
Three Dimensional Simulations

Accurate numerical simulations of vortex rings impinging on flat boundaries revealed the same features observed in experiments. The results for the impact with a free-slip wall compared very well with previous numerical simulations that used spectral methods, and were also in qualitative agreement with experiments. The present simulation is mainly devoted to studying the more realistic case of rings interacting with a no-slip wall, experimentally studied by Walker et al. (1987). All the Reynolds numbers studied showed a very good agreement between experiments and simulations, and, at Rev > 1000 the ejection of a new ring from the wall was seen. Axisymmetric simulations demonstrated that vortex pairing is the physical mechanism producing the ejection of the new ring. Three-dimensional simulations were also performed to investigate the effects of azimuthal instabilities. These simulations have confirmed that high-wavenumber instabilities originate in the compression phase of the secondary ring within the primary one. The large instability of the secondary ring has been explained by analysis of the rate-of-strain tensor and vorticity alignment. The differences between passive scalars and the vorticity field have been also investigated.

scholarly journals Stress-strain state of a composite near rectangular inclusion

2018 ◽  
Vol 243 ◽  
pp. 00021
Author(s):  
Pavel Pisarev ◽  
Aleksandr Anoshkin ◽  
Vladislav Ashihmin
Keyword(s):  
Numerical Simulations ◽  
Numerical Experiments ◽  
Strain State ◽  
Maximum Stress ◽  
Three Dimensional ◽  
Thermoplastic Composite ◽  
Model Construction ◽  
Stress Strain ◽  
Stress Strain State ◽  
Rectangular Inclusion

In this research we developed a technique for calculating the stress-strain state of a model construction from a thermoplastic composite material with an embedded piezoactuator. Numerical simulations of the model construction stress-strain state with different arrangement of piezoactuators: upper and middle,-were performed. Numerical simulations were carried out in a three-dimensional setting taking into account the complete technological scheme of laying and anisotropy of the properties of reinforcing layers. The results of numerical experiments revealed the areas of maximum stress. Recommendations for the MFC’s embedding into composite materials were formulated.

scholarly journals A fully consistent and conservative vertically adaptive coordinate system for SLIM 3D v0.4, a DG finite element hydrodynamic model, with an application to the thermocline oscillations of Lake Tanganyika

2017 ◽  
Author(s):  
Philippe Delandmeter ◽  
Jonathan Lambrechts ◽  
Vincent Legat ◽  
Valentin Vallaeys ◽  
Jaya Naithani ◽  
...  
Keyword(s):  
Finite Element ◽  
Lake Tanganyika ◽  
Three Dimensional ◽  
Adaptive Mesh ◽  
Vertical Movement ◽  
Finite Difference Schemes ◽  
Arbitrary Lagrangian Eulerian ◽  
Vertical Diffusion ◽  
Continuity Equations ◽  
Ale Formulation

Abstract. The discontinuous Galerkin (DG) finite element method is well suited to the modelling, with a relatively small number of elements, of three-dimensional flows exhibiting strong velocity or density gradients. Its performance can be highly enhanced by having recourse to r-adaptivity. Here, a vertical adaptive mesh method is developed for DG finite elements. This method, originally designed for finite difference schemes, is based on the vertical diffusion of the mesh nodes, with the diffusivity controlled by the density jumps at the mesh element interfaces. The mesh vertical movement is determined by means of a conservative Arbitrary Lagrangian–Eulerian (ALE) formulation. Though conservativity is naturally achieved, tracer consistency is obtained by a suitable construction of the mesh vertical velocity field, which is defined in such a way that it is fully compatible with the tracer and continuity equations at a discrete level. The vertically adaptive mesh approach is implemented in the geophysical and environmental flow model SLIM 3D (www.climate.be/slim). Idealised benchmarks, aimed at simulating the oscillations of a sharp thermocline, are dealt with. Then, the relevance of the vertical adaptivity technique is assessed by simulating thermocline oscillations of Lake Tanganyika. The results are compared to measured vertical profiles of temperature, showing similar stratification and outcropping events.

3D Finite Element Analysis of Prestressed Cutting

2012 ◽  
Vol 591-593 ◽  
pp. 766-770 ◽  
Author(s):  
Rui Tao Peng ◽  
Fang Lu ◽  
Xin Zi Tang ◽  
Yuan Qiang Tan
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Bearing Steel ◽  
Arbitrary Lagrangian Eulerian ◽  
Machined Surface ◽  
Element Analysis ◽  
Simulation Techniques ◽  
Ale Formulation

In order to reveal the adjustment principle of prestressed cutting on the residual stress of hardened bearing steel GCr15, a three-dimensional thermal elastic-viscoplastic finite element model was developed using an Arbitrary Lagrangian Eulerian (ALE) formulation. Several key simulation techniques including the material constitutive model, constitutive damage law and contact with friction were discussed, simulation of chip formation during prestressed cutting was successfully conducted. At the prestresses of 0 MPa, 341 MPa and 568 MPa, distributions of residual stress on machined surface were simulated and experimentally verified. The results indicated that residual compressive stress on machined surface were achieved and actively adjusted by utilizing the prestressed cutting method; meanwhile, within the elastic limit of bearing steel material, the higher applied prestress leads to the more prominent compressive residual stress in the surface layer and subsequently the higher fatigue resistance of the part.

Ratchet mechanism of drops climbing a vibrated oblique plate

2017 ◽  
Vol 835 ◽  
Author(s):  
Hang Ding ◽  
Xi Zhu ◽  
Peng Gao ◽  
Xi-Yun Lu
Keyword(s):  
Contact Angle ◽  
Theoretical Analysis ◽  
Numerical Simulations ◽  
Contact Angle Hysteresis ◽  
Three Dimensional ◽  
Direct Numerical Simulations ◽  
Ratchet Mechanism ◽  
Wetted Area ◽  
First Time ◽  
Good Agreement

In this paper, we investigate the ratchet mechanism of drops climbing a vibrated oblique plate based on three-dimensional direct numerical simulations, which for the first time reproduce the existing experiment (Brunet et al., Phys. Rev. Lett., vol. 99, 2007, 144501). With the help of numerical simulations, we identify an interesting and important wetting behaviour of the climbing drop; that is, the breaking of symmetry due to the inclination of the plate with respect to the acceleration leads to a hysteresis of the wetted area in one period of harmonic vibration. In particular, the average wetted area in the downhill stage is larger than that in the uphill stage, which is found to be responsible for the uphill net motion of the drop. A new hydrodynamic model is proposed to interpret the ratchet mechanism, taking account of the effects of the acceleration and contact angle hysteresis. The predictions of the theoretical analysis are in good agreement with the numerical results.

Computation of the Flow Field of Transonic Axial Compressor by Steady Arbitrary Lagrangian Eulerian Formulation

2008 ◽  
Author(s):  
Adel Ghenaiet ◽  
Nouredine Djeghri
Keyword(s):  
Flow Field ◽  
Three Dimensional ◽  
Axial Compressor ◽  
Arbitrary Lagrangian Eulerian ◽  
Viscous Effects ◽  
Stability Range ◽  
Transonic Compressor ◽  
Ale Formulation ◽  
Transonic Axial Compressor ◽  
Residual Smoothing

This paper presents a multi-block solver dealing with an inviscid three dimensional compressible flow through a transonic compressor blading. For efficient computations of the 3D time dependant Euler equations, this solver that we have developed has been cast within a stationary ALE ‘Arbitrary Lagrangian Eulerian’. The main contribution of this paper is by consolidating this ALE formulation, to alleviate the shortcomings linked to rotation effects and the mixed relative subsonic–supersonic inlet flow conditions, which are now simply implemented through an absolute subsonic flow velocity. The finite volume based solver is using the central differencing scheme known as JST (Jameson-Schmidt-Turkel). The explicit multistage Runge-Kutta algorithm is used as a pseudo time marching to the steady-state, coupled with two convergence accelerating techniques; the variable local time-stepping and the implicit residual smoothing procedure. The adaptive implicit residual smoothing has extended the stability range of this explicit scheme, and proved to be successful in accelerating the rate of convergence. This code is currently being extended to include viscous effects, where fluxes are discretized based on Green’s theorem. To support this solver, an H type grid generator based on algebraic and elliptic methods has been developed. The segmentation of the complete domain into smaller blocks has provided full topological and geometrical flexibilities. The code was used to compute the flow field of a transonic axial compressor NASA rotor 37, and comparisons between the calculations and some available experimental data under the design speed and part speed, show qualitatively good agreement.

Prelimenary Study on Thermomechanical Modelling of Cutting Process

2011 ◽  
Vol 383-390 ◽  
pp. 6741-6746
Author(s):  
Wan Masrurah Bt Hairudin ◽  
Mokhtar B. Awang
Keyword(s):  
Maximum Stress ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Maximum Temperature ◽  
Arbitrary Lagrangian Eulerian ◽  
Element Analysis ◽  
Ale Formulation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, thermo mechanical modelling of cutting process has been developed using a commercially available finite element analysis software, ABAQUS. A 2-D orthogonal cutting has been modelled using Arbitrary Lagrangian-Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. This study is aimed at temperature and stresses distributions during machining of AISI 1045 steel with different rake angles; α=0° and α= -10°. The results showed that the maximum stress for 0° and -10° are 963MPa and 967MPa while the maximum temperature results shown that 771°C and 347°C.

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