scholarly journals Finite Element Analysis of Extrusion Process for Magnesium Alloy Internal Threads with Electromagnetic Induction-Assisted Heating and Thread Performance Research

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2170 ◽  
Author(s):  
Meng Liu ◽  
Zesheng Ji ◽  
Rui Fan ◽  
Xingguo Wang
Keyword(s):  
Finite Element ◽  
Magnesium Alloy ◽  
Electromagnetic Induction ◽  
High Speed ◽  
Heating Temperature ◽  
Equivalent Stress ◽  
Hole Diameter ◽  
Process Conditions ◽  
Forming Process ◽  
Element Analysis

The casting magnesium alloy AZ91D cannot be extruded at room temperature. This paper presents a process for extruding internal threads using AZ91D heated by electromagnetic induction. The feasibility of the process is verified by finite element simulation and experiments. Using DEFORM-3D to simulate the process of extruding a M12 × 1.25 mm threaded hole by electromagnetic induction-assisted heating, the equivalent stress-strain and material flow law in the process of thread deformation was analyzed and verified by experiments. Three parameters—hole diameter, machine speed and heating temperature—were considered to study the influence of different process conditions on the forming torque. The results show that a heating temperature above 523 K can improve the plasticity of AZ91D. The hole diameter has an important influence on the forming torque. The forming process is not suitable for high-speed machining. The surface metal of the thread formed by this process has a strong deformation layer, which can improve the strength and hardness of the thread.

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

FORMING LIMIT OF AZ31B MAGNESIUM ALLOY SHEET IN THE DEEP DRAWING WITH CROSS-SHAPED DIE

2008 ◽  
Vol 22 (31n32) ◽  
pp. 6045-6050 ◽  
Author(s):  
HEON YOUNG KIM ◽  
SUN CHUL CHOI ◽  
HYUNG JONG KIM ◽  
SEOK MOO HONG ◽  
YONG SEUNG SHIN ◽  
...  
Keyword(s):  
Finite Element ◽  
Magnesium Alloy ◽  
Deep Drawing ◽  
Temperature Deformation ◽  
Dome Height ◽  
Forming Limit ◽  
Process Conditions ◽  
Geometrical Parameters ◽  
Element Analysis ◽  
Az31b Magnesium Alloy

Magnesium alloy sheets are usually formed at temperatures between 150 and 300°C because of their poor formability at room temperature. In the present study, the formability of AZ31B magnesium alloy sheets was investigated by the analytical and experimental approaches. First, tensile tests and limit dome height tests were carried out at several temperatures between 25 and 300°C to get the mechanical properties and forming limit diagram (FLD). A FLD-based criterion considering the material temperature during deformation was used to predict the forming limit from a finite element analysis (FEA) of the cross-shaped cup deep drawing process. This criterion proved to be very useful in designing the geometrical parameters of the forming tools and determining optimal process conditions such as tool temperatures and blank shape by the comparison between finite element temperature-deformation analyses and physical try-out. The heating and cooling channels were also optimally designed through heat transfer analyses.

An Elasto-Plastic Finite Element Analysis of the Hat-Type Drawing Process of Sheet Metal

2006 ◽  
Vol 505-507 ◽  
pp. 709-714
Author(s):  
Tsung Chia Chen ◽  
You Min Huang
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Moving Boundary ◽  
Contact Problems ◽  
Computer Code ◽  
Plastic State ◽  
Process Conditions ◽  
Drawing Process ◽  
Forming Process ◽  
Element Analysis

This study aims to clarify the process conditions of the hat-type drawing of a sheet metal of steel. It provides a model that predicts not only the correct punch load for drawing, but also the precise final shape of products after unloading, based on the tensile properties of the material and the geometry of the tools used. An elasto-plastic incremental finite-element computer code, based on an updated Lagrangian formulation, was developed to simulate the hat-type drawing of sheet metal. In particular, selective reduced integration was adopted to formulate the stiffness matrix. The extended r-minimum technique was used to deal with the elasto-plastic state and contact problems at the tool-metal interface. A series of simulations were performed to validate the formulation in the theory, leading to the development of the computer codes. The whole deformation history and the distribution of stress and strain during the forming process were obtained by carefully considering the moving boundary condition in the finite-element method. Results in this study clearly demonstrated that the computer code for simulating the hat-type drawing process was efficient.

Experimental Investigation and Finite Element Analysis on Electromagnetic Compression Forming Processed Aluminum Alloy Tubes

2011 ◽  
Vol 110-116 ◽  
pp. 1706-1710
Author(s):  
Selvam Rajiv ◽  
Karibeeran Shanmuga Sundaram ◽  
Pablo Pasquale
Keyword(s):  
Experimental Investigation ◽  
Finite Element ◽  
Aluminum Alloy ◽  
High Speed ◽  
High Energy ◽  
Work Piece ◽  
Outer Diameter ◽  
Forming Process ◽  
Element Analysis ◽  
Electromagnetic Compression

Electromagnetic forming (EMF) is a high energy rate forming (HERF) process. It is a high speed forming process using a pulsed magnetic field to form work pieces made of metals such as copper or aluminum alloys with high electrical conductivity. The work piece to be deformed will be located within the effective area of the tool coil so that the resulting type of stress during the forming process is determined by the type of coil used and its arrangement as related to the component. Tubular or structural components can be narrowed by means of compression coils or widened by means of expansion coils, where as sheet metal can be deformed by flat coils. In this work, the experimental investigation and simulation of electromagnetic compression forming of aluminum alloy tubes is studied. The aim of the paper was to verify the results from Finite element methods with experimental data. Experiments were conducted on Tubes of outer diameter 40 mm and wall thickness of 2 mm with a nominal tensile strength of 214 MPa. The tube was compressed using a 4 turn helical actuator discharge that can be energied up to 20 kJ. A field shaper made of aluminum was used. A Maximum reduction of 15.85% in diameters were measured. The same problem was simulated in ANSYS using static coupled electromagnetic analysis. The results of the Simulation showed good correlation with experimental results.

Finite Element Analysis of Cold Expanding of Hollow Thin-Wall Tube

2011 ◽  
Vol 460-461 ◽  
pp. 44-47
Author(s):  
Wei Hua Kuang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Stress Distribution ◽  
Equivalent Stress ◽  
Element Model ◽  
Thin Wall ◽  
Forming Process ◽  
Element Analysis ◽  
Simulation Step ◽  
The Finite Element Analysis

The cold expanding diameter process was simulated by the software of DEFORM. The finite element model of tube and dies were built. The object position definition, the inter object setting, movement definition and simulation step were correctly set. The deformation, total velocity distribution and equivalent stress distribution were predicted. The numerical simulation results showed that the finite element analysis could exactly describe the plastic deformation and stress distribution during the forming process.

An Elasto-Plastic Finite Element Analysis of the Radial Compression of Aluminium Tube between Rigid Plates

2011 ◽  
Vol 264-265 ◽  
pp. 166-171
Author(s):  
Tsung Chia Chen
Keyword(s):  
Finite Element ◽  
Moving Boundary ◽  
Contact Problems ◽  
Computer Code ◽  
Plastic State ◽  
Process Conditions ◽  
Radial Compression ◽  
Forming Process ◽  
Element Analysis ◽  
Aluminum Tube

This study aims to clarify the process conditions of the radial compression of aluminum tube. It provides a model that predicts not only the correct punch load for compression, but also the precise final shape of products after unloading, based on the compression properties of the material and the geometry of the tools used. An elasto-plastic incremental finite-element computer code, based on an updated Lagrangian formulation, was developed to simulate the radial compression of aluminum tube. In particular, selective reduced integration was adopted to formulate the stiffness matrix. The extended r-minimum technique was used to deal with the elasto-plastic state and contact problems at the tool-metal interface. A series of simulations were performed to validate the formulation in the theory, leading to the development of the computer codes. The whole deformation history and the distribution of stress and strain during the forming process were obtained by carefully considering the moving boundary condition in the finite-element method. Results in this study clearly demonstrated that the computer code for simulating the radial compression of aluminum tube was efficient.

On Saw-Tooth Chip Formation in High Speed Cutting GH4169

2007 ◽  
Vol 10-12 ◽  
pp. 359-363 ◽  
Author(s):  
Dong Jin Zhang ◽  
Gang Liu ◽  
X. Sun ◽  
Ming Chen
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
High Yield ◽  
Forming Process ◽  
Element Analysis ◽  
High Speed Cutting ◽  
Nickel Based Superalloy ◽  
Wide Range

The nickel-based superalloy GH4169 is a typical difficult-to-cut material, but it has been used in a good many kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at the temperature below 650°C. In this paper, finite element method (FEM) was introduced to study the saw-tooth chip forming process in detail when machining nickel-based superalloy GH4169. By the way of Lagrangian visco-elastic plastic approach, adiabatic shear band (ASB) was simulated in high speed machining condition by general commercial finite element code, and the mechanism of the adiabatic shearing phenomenon at primary shear zone was analyzed with the help of finite element analysis (FEA). The comprehensive comparisons of saw-tooth chip morphology under a wide range of cutting speed were also presented.

Three Dimensional Finite Element Analysis of Staggered Backward Flow Forming Process

2013 ◽  
Author(s):  
Hemant Shinde ◽  
Pushkar Mahajan ◽  
Ramesh Singh ◽  
K. Narasimhan
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Process Conditions ◽  
State Variables ◽  
Forming Process ◽  
Flow Forming ◽  
Element Analysis ◽  
Cold Forming ◽  
Cylindrical Workpiece ◽  
Backward Flow Forming

Flow forming is one of the cold forming processes which is mainly used to produce thin-walled high-precision tubular components. A three dimensional coupled-field thermo-mechanical finite element model for staggered three-roller backward flow forming of a cylindrical workpiece of MDN-250 maraging steel has been developed using Abaqus/Explicit. In this model, the effect of tip radius of the rollers and friction between the rollers and the workpiece has been considered. The bottom of the workpiece is fixed in the axial direction so that diametral reduction and the axial elongation can be studied. Simulations have been carried out at different process conditions to study the state variables, such as stresses and strains obtained during the deformation. The model has been benchmarked with the experimental results for thickness reduction and the error in the thickness prediction is limited to 4%. The roll forces have been benchmarked against analytical formulation and a difference of 13–20% has been observed. The effect of flow forming process variables, such as feed rate and reduction ratio on the stress/strain distribution and roll forces have been studied. The results show that the roll forces increase at higher feed rates and higher reduction ratios whereas the equivalent strains increase at lower feed rates and higher reduction ratios. In addition, a parametric study has been conducted to study ovality, diametral growth, roll forces, stresses and strains as a function of process parameters.

Finite-Element Analysis of the Magnetostatic Field of a Coaxial Magnetic Gear Device

2015 ◽  
Vol 764-765 ◽  
pp. 289-293
Author(s):  
Yi Chang Wu ◽  
Han Ting Hsu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Magnetic Flux ◽  
High Speed ◽  
Field Analysis ◽  
Element Analysis ◽  
Magnetostatic Field ◽  
Speed Reduction ◽  
Dimensional Finite Element ◽  
Magnetic Gear

This paper presents the magnetostatic field analysis of a coaxial magnetic gear device proposed by Atallah and Howe. The structural configuration and speed reduction ratio of this magnetic gear device are introduced. The 2-dimensional finite-element analysis (2-D FEA), conducted by applying commercial FEA software Ansoft/Maxwell, is performed to evaluate the magnetostatic field distribution, especially for the magnetic flux densities within the outer air-gap. Once the number of steel pole-pieces equals the sum of the pole-pair numbers of the high-speed rotor and the low-speed rotor, the coaxial magnetic gear device possesses higher magnetic flux densities, thereby generating greater transmitted torque.

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