scholarly journals Analysis and Control of Twist Defects of Aluminum Profiles with Large Z-Section in Roll Bending Process

Metals ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 31 ◽  
Author(s):  
Anheng Wang ◽  
Hongqian Xue ◽  
Emin Bayraktar ◽  
Yanli Yang ◽  
Shah Saud ◽  
...  
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Element Model ◽  
Effective Control ◽  
Curvature Radius ◽  
3D Fem ◽  
Fe Method ◽  
Element Analysis ◽  
Roll Bending ◽  
Bending Process

This paper focuses on the twist defects and the control strategy in the process of four-roll bending for aluminum alloy Z-section profiles with large cross-section. A 3D finite element model (3D-FEM) of roll bending process has been developed, on the premise of the curvature radius of the profile, the particularly pronounced twist defects characteristic of 7075-O aluminum alloy Z-section profiles were studied by FE method. The simulation results showed that the effective control of the twist defects of the profile could be realized by adjusting the side roller so that the exit guide roll was higher than the entrance one (the side rolls presented an asymmetric loading mode with respect to the main rolls) and increasing the radius of upper roll. Corresponding experimental tests were carried out to verify the accuracy of the numerical analysis. The experimental results indicated that control strategies based on finite element analysis (FEA) had a significant inhibitory function on twist defects in the actual roll bending process.

Experimental and Numerical Investigation on Filling Roll Bending of Aluminum Alloy Integral Panel

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Han Xiao ◽  
Shi-hong Zhang ◽  
Jin-song Liu ◽  
Ming Cheng ◽  
Hong-xi Liu
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Numerical Methods ◽  
Process Parameters ◽  
Element Model ◽  
Geometric Accuracy ◽  
Roll Bending ◽  
Bending Process ◽  
Simulation Results ◽  
Deformation Homogeneity

Integral panels are widely used in aerospace industries. A filling roll bending process is proposed to form integral panels. Filling roll bending experiments of aluminum alloy integral panels were carried out. A 3D elastic–plastic finite element model of filling roll bending process was established and validated by experiment. The effects of filler and process parameters on the deformation homogeneity of the panels were analyzed by using experimental and numerical methods. The results indicate that the filler can improve the deformation homogeneity. With the increasing of the displacement of the top-roller from 5 mm to 40 mm, the experimental and simulation bending radii with filler all reduce, the experimental results reduce from 5806 mm to 190 mm, the simulation results reduce from 5924 mm to 199 mm, and the simulation springback rates with filler reduce from 0.92% to 0.15%. It is proved that high geometric accuracy of the integral panels can be obtained by using filling roll bending process.

Finite Element Analysis of Cold Bend Pipes Under Bending Loads

2010 ◽  
Author(s):  
Millan Sen ◽  
Roger Cheng
Keyword(s):  
Finite Element ◽  
Local Buckling ◽  
Vertical Direction ◽  
Element Model ◽  
Element Analysis ◽  
Cold Bending ◽  
Bending Process ◽  
Cold Bends ◽  
Full Scale Tests ◽  
The Right

Cold bends are required in pipelines at locations of changes in horizontal or vertical direction in the right of way. Due to this change of direction, pipeline deformations caused by geotechnical or operational loading conditions tend to accumulate at the site of cold bends. These deformations may become sufficient to cause local buckling at the bend. For pipeline design, it is important to understand the level of deformation that a cold bend can accumulate prior to local buckling so that the strain capacity can be compared to the expected pipeline deformations. Evaluating the buckling strain of cold bends is extremely complex due to the residual stresses, ripples, and material transformations cause by the cold bending process. Accordingly a finite element model was developed herein. This model accounted for the cold bend geometry, initial imperfections, and the material transformations caused by the cold bending process. This model was validated against 7 full scale tests of cold bend pipes that were subjected to bend loading and internal pressure. The global and local behavior of this model exhibited reasonable correlation against the tests.

Finite Element Analysis for Comprehensive Residual Stress of 7075 Aluminum Alloy Thick Plate

2010 ◽  
Vol 154-155 ◽  
pp. 1255-1261
Author(s):  
Hai Yan Li ◽  
Yi Du Zhang ◽  
Hong Wei Zhang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Thick Plate ◽  
Coupling Effect ◽  
Element Model ◽  
Forming Process ◽  
Element Analysis ◽  
Field Coupling ◽  
Simulation And Experiment

Based on “physical field coupling” finite element method, the generation of residual stress and interactive coupling effect were analyzed during the forming process of aluminum alloy thick-plate. Therefore, comprehensive residual stress generated from rolling, quenching and stretching was obtained. The finite element model was proved effective by comparing the results of simulation and experiment. Results show that percent reduction has significant influence to the distribution and magnitude of rolling stress; There is a coupling effect between rolling stress and quenching stress, which represents a basic state; Furthermore, after stretching the distribution of coupling stress remains, but the value reduces greatly; The residual stress has got the minimum, when stretching is near 3%.

Finite Element Analysis on Spread for In-plane Roll-bending Process

2010 ◽  
Author(s):  
Z. J. Li ◽  
H. Yang ◽  
F. Barlat ◽  
Y. H. Moon ◽  
M. G. Lee
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Element Analysis ◽  
Roll Bending ◽  
Bending Process

Effects of Air Bending Parameters on Spingback Using Finite Element Analysis

2013 ◽  
Vol 423-426 ◽  
pp. 978-983
Author(s):  
Xie Li
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Internal Stresses ◽  
Element Analysis ◽  
Air Bending ◽  
Bending Process ◽  
Punch Radius ◽  
The Finite Element Model

Springback is a common phenomenon in air bending of sheet metal forming, caused by the elastic redistribution of the internal stresses during unloading. It has been recognized that springback is essential for the design of the air bending. Traditionally, the values of springback is obtained for air bending parameters from handbook tables or springback graphs. However, the handbook tables or springback graphs are obtained using experiments and it is a time consuming processes. In this paper, a finite element model has been used to analyze the air bending process. Some experiments are carried out on ST12 materials, and the finite element model is validated comparing with experiments. In the present research the influence of process variables such as punch radius, die radius and die on springback are discussed using finite element analysis. Thus, the presented results of this research provide a basis of design to improve forming quality.

Computer Simulation of Deep Drawing Process for a Laminated Composite Cup

2007 ◽  
Author(s):  
Tushar Naik ◽  
Zhong Hu
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Deep Drawing ◽  
Laminated Composites ◽  
Laminated Composite ◽  
Element Model ◽  
Drawing Process ◽  
Forming Process ◽  
Element Analysis ◽  
Deep Drawing Process

The anisotropic nature of laminated composites creates a unique opportunity and also a great challenge for tailoring their behavior during the forming processes according to the design requirements. In this work, design and simulation of a deep drawing process for fiber-reinforced laminated composites were conducted by using finite element analysis. The effects of the fiber orientation and stacking order on the deep drawing process were investigated based on the basic understanding of forming process of the isotropic aluminum alloy (Al-1100) and laminated composite material (Grilon RVZ-15H nylon/glass). A three dimensional finite element model incorporating layered structural laminates with various fiber orientations was developed. The load-stroke relationship, changes in thickness, and stress-strain distribution were investigated and compared for both aluminum alloy and laminated composites of [0]12, [0/90]6 and [0/90/45/135]3, which can be employed for detailed design and process optimization.

The Numerical Simulation of the Aluminum Alloy Processing

2011 ◽  
Vol 188 ◽  
pp. 590-595
Author(s):  
B.J. Xiao ◽  
Cheng Yong Wang ◽  
Ying Ning Hu ◽  
Yue Xian Song
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Element Model ◽  
Adaptive Meshing ◽  
Surface Residual Stress ◽  
Element Analysis ◽  
The Impact

A two-dimensional orthogonal thermal-mechanical finite element model by Deform2D finite element analysis software is established in the article. By the adaptive meshing technique, not only cutting process but also the effect on the process of aluminum alloy Al6061-T6 processing as friction coefficient changing is simulated. The simulation shows that the friction coefficient has significant effect on the cutting temperature and cutting force, and the effect is nonlinear. With the increasing of the friction coefficient, the cutting temperature and cutting force will both increase. The impact the friction coefficient has on the surface residual stress is much smaller than the impact on the cutting temperature and cutting force.

The Finite Element Analysis for Dimensional Accuracy in Roll Bending of Aluminum-Polymer Laminated Sheet

2013 ◽  
Vol 390 ◽  
pp. 574-578
Author(s):  
Qing Shuai Kong ◽  
Zhong Qi Yu ◽  
Yi Xi Zhao ◽  
Shu Hui Li
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Simulation Model ◽  
Sheet Material ◽  
Dimensional Accuracy ◽  
Elastic Model ◽  
Element Analysis ◽  
Roll Bending ◽  
The Finite Element Analysis ◽  
Bending Process

The padding assisted roll bending technology is the main method to manufacture the cylinder structure with variable thickness. In order to study the deformation behavior of the padding assisted roll bending process, a numerical simulation model of the aluminum-polymer laminated sheet three-roll bending is established based on the finite element method. In the numerical simulation model, the sheet material Al2024-T3 is selected elasto-plastic model, and the padding material nylon PA6-G is elastic model. Based on the simulation results, the following conclusions are drawn: the cylinder radius of the sheet Al2024-T3 decreases with decreasing of the ratio of the nylon PA6-G or increasing of the stroke of the upper roller; And in the direction of bend line, an appropriate thickness compensation of the nylon PA6-G can improve the consistency of the curvature of the sheet Al2024-T3.

Finite Element Analysis and Shape Optimization of Aluminum Alloy Automobile Energy-Absorbing Components

2012 ◽  
Vol 249-250 ◽  
pp. 954-957
Author(s):  
Yan Jie Liu ◽  
Lin Ding ◽  
Qing Fen Li ◽  
Dan Wang
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Cross Section ◽  
Simulation Analysis ◽  
Fe Model ◽  
Fe Method ◽  
Element Analysis ◽  
Section Shape ◽  
Thin Walled Tube ◽  
Energy Absorbing

In the present work, the structure optimum design and simulation analysis of aluminum alloy automobile energy-absorbing components was carried out by using Finite Element (FE) method. The numerical simulations were carried out using the software LS-DYNA. Automobile energy-absorbing components usually was made a mental thin walled tube. In the paper, the tube was adopted aluminum alloy material. The FE model of the tube was validated by comparing the theoretical results and FE model results. The good correlation of results obtained show that the numerical analyses are reliable. Attention was focused upon finding an optimum cross- section shape of the tube in order to improve the crashworthiness. Several types of cross- section were studied and compared. Results show that the crashworthiness of the tube improved obviously when square cross section with the grooves was adopted.

3D FEM Simulation and Experimental Research of Springback in Bending Process of Aluminum Alloy Sheet

2010 ◽  
Vol 431-432 ◽  
pp. 487-490
Author(s):  
Xia Jin ◽  
Shi Hong Lu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Sheet Metal ◽  
Manufacturing Industry ◽  
Elastic Recovery ◽  
3D Fem ◽  
Element Analysis ◽  
Comparison Results ◽  
Springback Angle

Bending of the aluminum alloy is one of the processes frequently applied during manufacture of aircraft sheet metal. The bending operation involves springback, which is defined as elastic recovery of the part during unloading. In manufacturing industry, it is still a practical and difficult problem to predict the final geometry of the part after springback and to design appropriate tools in order to compensate for springback. In this study, 3D commercially available finite element analysis (FEA) software-MARC is used to analyse bending and springback of different aluminium materials (LY12CZ) with different thickness. The amount of springback, total equivalent plastic strains and equivalent von mises stresses are obtained. Moreover, the relation between bent angle and springback angle, R/t ratio and springback angle are presented and discussed in detail.The comparison results of FEA result and experiment data indicate that the FEM (finite element analysis method) simulation is a power tool for the highly accurate prediction of springback behavior in sheet metal bending.

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