scholarly journals Theoretical and Experimental Analysis of a New Process for Forming Flanges on Hollow Parts

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4088
Author(s):  
Grzegorz Winiarski ◽  
Andrzej Gontarz ◽  
Grzegorz Samołyk
Keyword(s):  
Software Package ◽  
Large Diameter ◽  
Testing Machine ◽  
Experimental Tests ◽  
New Method ◽  
The Finite Element Method ◽  
New Process ◽  
3D Software ◽  
Deform 3D ◽  
Extrusion Method

The paper presented a new method for forming flanges on hollow parts by incremental radial extrusion. In the classic process of radial extrusion, additional rings were used to limit the free flow of material in the radial direction. The flange was formed progressively, using rings of increasing diameters. The proposed method was verified by numerical analysis and experimental tests. The numerical calculations were performed by the finite element method using the Deform-3D software package. Tubes made of aluminum alloy EN AW 6060 were used as billets. Laboratory tests were carried out using the Instron 1000 HDX testing machine. The objective of the study was to determine the validity of the proposed flange extrusion method. Results demonstrated that the new method made it possible to produce flanges with a relatively large diameter and uniform thickness, confirming the effectiveness of the proposed forming technique.

Theoretical and Experimental Research on a Method for Producing a Triangular Rosette-Shaped Flange

2014 ◽  
Vol 622-623 ◽  
pp. 1166-1172 ◽  
Author(s):  
Andrzej Gontarz ◽  
Zbigniew Pater ◽  
Janusz Tomczak ◽  
Grzegorz Winiarski
Keyword(s):  
Experimental Tests ◽  
Strength Properties ◽  
Production Costs ◽  
New Method ◽  
Propeller Shaft ◽  
Hollow Shaft ◽  
3D Software ◽  
Forging Press ◽  
Deform 3D ◽  
Lower Production

The paper presents a new method for forming a hollow shaft with a triangular rosette-shaped flange on its end. The part being investigated is used as a propeller shaft in helicopters. The product must be monolithic, therefore it cannot be produced by methods which consist in joining a flange with a tube. Up till now, such shafts have been produced by machining from solid barstock, the process which generates material losses exceeding 90%. The application of the proposed flanging method results in a significant reduction in both material and labour consumption, which leads to lower production costs. Due to beneficial texture of the shaft flange, shafts produced by this method exhibit better strength properties than shafts produced by machining. The paper presents the results of a numerical analysis of the flanging process, performed using DEFORM-3D software. Also, experimental tests were conducted using a three-slide forging press. Theoretical and experimental results obtained confirm the effectiveness of the new method for forming this part.

Finite element method research of thermofriction Cutting-off with pulsed cooling

2020 ◽  
Author(s):  
K.T. Sherov ◽  
S.S. Aynabekova ◽  
S. O. Tusupova ◽  
A.A. Sagitov ◽  
E.B. Imanbaev
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Software Package ◽  
The Finite Element Method ◽  
Cutting Mechanism ◽  
3D Software ◽  
Deform 3D ◽  
Element Method

The results of a study of the thermofriction cutting-off method with pulsed cooling, obtained by modeling the process by the finite element method using the Machining module of the Deform 3D software package, are presented. The hypothesis put forward earlier about the cutting mechanism with this method is confirmed. Keywords thermofriction cutting-off, pulsed cooling, finite element method, cutting mechanism. [email protected]

Analysis of a new process of forging a 2017A aluminium alloy connecting rod

2021 ◽  
pp. 1-32
Author(s):  
Grzegorz Winiarski ◽  
Anna Dziubinska
Keyword(s):  
Aluminium Alloy ◽  
The Finite Element Method ◽  
Connecting Rod ◽  
Sand Cast ◽  
Input Material ◽  
Lower Strain ◽  
New Process ◽  
Billet Material ◽  
Hammer Forging ◽  
Deform 3D

Abstract The paper presents the results of a theoretical analysis of a new process of hammer forging of a connecting rod and the technology currently used. In the industry at present connecting rods are forged from extruded rods. The new forging technology assumes the use of a billet in the form of a cast preform. For the calculations, it has been assumed that the billet material will be a Ø30 x 148 mm rod and a cast preform. Two variants of preforms have been modelled, from which products of the assumed geometry with different degree of strain are obtained. Calculations were made using the finite element method in the Deform 3D program. The input material was 2017A aluminium alloy in the form of rods and sand cast preforms. On the basis of the conducted research it was found that the use of cast preforms reduces material waste by about 80% in relation to the technology of forging from the bar, and reduces the energy consumption of the process by about 75%. Both geometrical variants of the forging preforms ensure obtaining a forging with the assumed shape and dimensions, although forging from the forging preform with a smaller degree of strain seems to be a safer variant in terms of the possibility of cracking of the material. This is supported by the lower strain and Cockcroft-Latham integral values.

Improving the honing accuracy of the holes of stepped thin-walled cylinders

2021 ◽  
pp. 49-54
Author(s):  
V.A. Ogorodov
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Software Package ◽  
The Finite Element Method ◽  
Radial Forces ◽  
Thin Walled ◽  
Hole Machining ◽  
Deform 3D ◽  
Walled Cylinder

Different ways of fixing of stepped thin-walled cylinders during honing are analyzed. The conditions for increasing the accuracy of hole machining are determined on the basis of unevenness of cylinder deformations from clamping forces and radial forces simulating cutting forces. The studies used the finite element method and the DEFORM-3D V6.1 software package. Keywords: honing, stepped thin-walled cylinder, hole, accuracy, fixing method, deformation, unevenness, DEFORM-3D V6.1 software package. [email protected]

scholarly journals Simulation of Ingotless Rolling-Extruding of Rods from Alloy of Al-Zr System and Investigating into their Properties

2020 ◽  
Vol 837 ◽  
pp. 3-8
Author(s):  
Vadim Bespalov ◽  
Sergey Sidelnikov ◽  
Ruslan Sokolov ◽  
Alexander Chumak ◽  
Denis Voroshilov ◽  
...  
Keyword(s):  
Experimental Data ◽  
Mechanical Properties ◽  
Computer Simulation ◽  
Software Package ◽  
Processing Parameters ◽  
Process Conditions ◽  
Laboratory Unit ◽  
Deformation Parameters ◽  
3D Software ◽  
Deform 3D

Computer simulation of the process of ingotless rolling-extruding (IRE) of aluminum alloy rods with a content of 0.15% zirconium in the Deform 3D software package performed. The temperature, speed and deformation parameters of the treatment of the investigated alloy determined under different process conditions. To check the adequacy of the models, rod samples were made on a CRE-200 laboratory unit at specified processing parameters. Using the Deform 3D software package, the forces acting on the rolls and the extruding die during the IRE determined and their comparison with tensometric experimental data presented. The mechanical properties, electrical resistivity of semi-finished products after processing by the method of ingotless rolling-extruding and for conditions of their heating to 230 °C investigated. Technological recommendations for the manufacture of deformed semi-finished products using the method of ingotless rolling-extruding are proposed.

Study of rolling in helical rolls by mathematical simulation with the DEFORM 3D software package

2011 ◽  
Vol 2011 (3) ◽  
pp. 188-193 ◽  
Author(s):  
N. V. Gubanova ◽  
F. R. Karelin ◽  
V. F. Choporov ◽  
V. S. Yusupov
Keyword(s):  
Mathematical Simulation ◽  
Software Package ◽  
3D Software ◽  
Deform 3D

scholarly journals Computer Simulation and Analysis of the Parameters of the Drawing Process of Thin Wire from the Alloy Pd-5Ni

2019 ◽  
Vol 805 ◽  
pp. 13-18
Author(s):  
Sergey Sidelnikov ◽  
Kristina Bindareva ◽  
Ekaterina Lopatina ◽  
Viktor Leonov ◽  
Denis Voroshilov ◽  
...  
Keyword(s):  
Software Package ◽  
Stable Process ◽  
Experimental Studies ◽  
Metal Alloys ◽  
Drawing Process ◽  
Thin Wire ◽  
Simulation Results ◽  
Increase In Productivity ◽  
3D Software ◽  
Deform 3D

This article represents the results of studies of the drawing thin wire from the alloy Pd-5Ni process. The studies used the software developed by the authors using the methods of calculating the drawing process and the computer model implemented in the DEFORM 3D software package. By way of calculation, a drawing route was determined, including 14 transitions, and the efforts of deforming the metal were found when producing wire with a diameter of 0.075. For this mode of deformation processing using the DEFORM 3D software package, we simulated the drawing process and established the temperature and stress distribution over the volume of the workpiece. The simulation results confirmed that the calculated safety factor for drawing is in the range of 2.85-3.43, which ensures a stable process of deformation of the metal without breaks and, as a consequence, an increase in productivity and yield of the suitable metal. Experimental studies have confirmed the adequacy of the developed model, so it can be used to analyze the process of drawing wire from other precious metal alloys. The results of the research are recommended to improve the production technology of thin wire from the alloy Pd-5Ni for the manufacture of catalytic gripping grids.

scholarly journals A Rotary Compression Process for Producing Hollow Gear Shafts

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5718
Author(s):  
Arkadiusz Tofil ◽  
Janusz Tomczak ◽  
Tomasz Bulzak ◽  
Zbigniew Pater ◽  
Marcin Buczaj ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Numerical Modeling ◽  
Material Flow ◽  
Software Package ◽  
Experimental Tests ◽  
Simulation Software ◽  
The Finite Element Method ◽  
Compression Process ◽  
Manufacturing Method ◽  
Stepped Shaft

This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft.

Simulation of High-Speed Cutting Using Deform 3D Software

2020 ◽  
Vol 299 ◽  
pp. 340-344
Author(s):  
Leonid Moiseevich Gurevich ◽  
Roman Novikov ◽  
Alexander Bannikov
Keyword(s):  
Software Package ◽  
High Speed ◽  
Rake Angle ◽  
Cutting Process ◽  
Work Piece ◽  
High Speed Cutting ◽  
3D Software ◽  
Deform 3D

The paper presents the result of the simulation of high-speed hot cutting process for ordinary and new saw geometry, using the Deform 3D software package. It was shown that the use of an additional side rake angle allows to controllably leave burr on one side of the work-piece only, and shift max stress from the saw gullets to the top of teeth.

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