scholarly journals Finite Element Simulation of High-Speed Blow Forming of an Automotive Component

Metals ◽  
2018 ◽  
Vol 8 (11) ◽  
pp. 901 ◽  
Author(s):  
Omid Majidi ◽  
Mohammad Jahazi ◽  
Nicolas Bombardier
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Complex Geometry ◽  
New Technology ◽  
Size Variation ◽  
Superplastic Forming ◽  
Thickness Variation ◽  
Strain Rates ◽  
Element Size ◽  
The Impact

High-speed blow forming (HSBF) is a new technology for producing components with complex geometries made of high strength aluminum alloy sheets. HSBF is considered a hybrid-superplastic forming method, which combines crash forming and gas blow forming. Due to its novelty, optimization of the deformation process parameters is essential. In this study, using the finite element (FE) code ABAQUS, thinning of an aluminum component produced by HSBF under different strain rates was investigated. The impact of element size, variation of friction coefficient, and material constitutive model on thinning predictions were determined and quantified. The performance of the FE simulations was validated through forming of industrial size parts with a complex geometry for the three investigated strain rates. The results indicated that the predictions are sensitive to the element size and the coefficient of friction. Remarkably, compared to a conventional power law model, the variable m-value viscoplastic (VmV) model could precisely predict the thickness variation of the industrial size component.

The Finite Element Analysis of Dynamic Interaction of High-Speed Shinkansen, the Rail, and Bridge

1993 ◽  
Author(s):  
Makoto Tanabe ◽  
Hajime Wakui ◽  
Nobuyuki Matsumoto
Keyword(s):  
Finite Element ◽  
Dynamic Response ◽  
High Speed ◽  
Response Analysis ◽  
Element Formulation ◽  
Element Analysis ◽  
Finite Element Program ◽  
The Finite Element Analysis ◽  
Element Program ◽  
The Impact

Abstract A finite element formulation to solve the dynamic behavior of high-speed Shinkansen cars, rail, and bridge is given. A mechanical model to express the interaction between wheel and rail is described, in which the impact of the rail on the flange of wheel is also considered. The bridge is modeled by using various finite elements such as shell, beam, solid, spring, and mass. The equations of motions of bridge and Shinkansen cars are solved under the constitutive and constraint equations to express the interaction between rail and wheel. Numerical method based on a modal transformation to get the dynamic response effectively is discussed. A finite element program for the dynamic response analysis of Shinkansen cars, rail, and bridge at the high-speed running has been developed. Numerical examples are also demonstrated.

scholarly journals Finite Element Analysis of Impact Energy on Spur Gear

2018 ◽  
Vol 225 ◽  
pp. 06011 ◽  
Author(s):  
Ismail Ali Bin Abdul Aziz ◽  
Daing Mohamad Nafiz Bin Daing Idris ◽  
Mohd Hasnun Arif Bin Hassan ◽  
Mohamad Firdaus Bin Basrawi
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Impact Energy ◽  
High Speed ◽  
Impact Test ◽  
Impact Load ◽  
Gear Tooth ◽  
Test Equipment ◽  
Element Analysis ◽  
The Impact

In high-speed gear drive and power transmission, system impact failure mode always occurs due to the sudden impact and shock loading during the system in running. Therefore, study on the amount of impact energy that can be absorbed by a gear is vital. Impact test equipment has been designed and modelled for the purpose to study the impact energy on gear tooth. This paper mainly focused on Finite Element Analysis (FEA) of impact energy that occurred during simulation involving the impact test equipment modelling. The simulation was conducted using Abaqus software on critical parts of the test equipment to simulate the impact event and generate impact data for analysis. The load cell in the model was assumed to be free fall at a certain height which gives impact load to the test gear. Three different type of material for the test gear were set up in this simulation. Results from the simulation show that each material possesses different impact energy characteristic. Impact energy values increased along with the height of load drop. AISI 1040 were found to be the toughest material at 3.0m drop that could withstand up to 44.87N.m of impact energy. These data will be used to validate data in physical experiments in further study.

scholarly journals Evaluation of Dynamic Load Factors for a High-Speed Railway Truss Arch Bridge

2016 ◽  
Vol 2016 ◽  
pp. 1-15 ◽  
Author(s):  
Ding Youliang ◽  
Wang Gaoxin
Keyword(s):  
Finite Element ◽  
Dynamic Load ◽  
High Speed ◽  
Field Monitoring ◽  
Generalized Extreme Value Distribution ◽  
Monitoring Data ◽  
Load Factor ◽  
High Speed Railway ◽  
Arch Bridge ◽  
The Impact

Studies on dynamic impact of high-speed trains on long-span bridges are important for the design and evaluation of high-speed railway bridges. The use of the dynamic load factor (DLF) to account for the impact effect has been widely accepted in bridge engineering. Although the field monitoring studies are the most dependable way to study the actual DLF of the bridge, according to previous studies there are few field monitoring data on high-speed railway truss arch bridges. This paper presents an evaluation of DLF based on field monitoring and finite element simulation of Nanjing DaShengGuan Bridge, which is a high-speed railway truss arch bridge with the longest span throughout the world. The DLFs in different members of steel truss arch are measured using monitoring data and simulated using finite element model, respectively. The effects of lane position, number of train carriages, and speed of trains on DLF are further investigated. By using the accumulative probability function of the Generalized Extreme Value Distribution, the probability distribution model of DLF is proposed, based on which the standard value of DLF within 50-year return period is evaluated and compared with different bridge design codes.

Interfacial Heat Transfer During Droplet Impact on a Solid Surface: Comparison of High-Resolution Laser Measurements With Finite-Element Simulations

2007 ◽  
Author(s):  
Rajneesh Bhardwaj ◽  
Jon P. Longtin ◽  
Daniel Attinger
Keyword(s):  
Heat Transfer ◽  
Fluid Dynamics ◽  
Finite Element ◽  
High Speed ◽  
Element Model ◽  
Deposition Process ◽  
Interfacial Heat Transfer Coefficient ◽  
Interfacial Heat Transfer ◽  
Laser Measurements ◽  
The Impact

The objective of this work is to understand the coupling of fluid dynamics and heat transfer during the impact of a millimeter-size water droplet on a flat, solid glass substrate. In this work, a finite-element model is presented which simulates the transient fluid dynamics and heat transfer during the droplet deposition process, considering Laplace forces on the liquid-gas boundary, and the dynamics of wetting. A novel, experimental laser-based method is used to measure temperatures at the solid-liquid interface. This method is based on a thermoreflectance technique and provides unprecedented temporal and spatial resolutions of 1 microsecond and 20 micrometer, respectively. Matching between simulations, temperature measurements and high-speed visualization allows the determination of the interfacial heat transfer coefficient.

Axial Impact Performance of Aluminium Thin Cylindrical Tube

2013 ◽  
Vol 315 ◽  
pp. 1-5 ◽  
Author(s):  
Perowansa Paruka ◽  
Waluyo Adi Siswanto
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Cylindrical Tube ◽  
Numerical Approach ◽  
Stress And Strain ◽  
Axial Impact ◽  
Cylindrical Structure ◽  
Impact Performance ◽  
Impact Simulation ◽  
The Impact

One of the important objectives in this research is investigating the behavior on the cylindrical tube structure via computer simulations. When a thin cylindrical structure is experienced an impact loading, the crushing process on impact can only be observed by a high speed camera. Recording the stress and strain data is also not possible experimentally. A numerical approach implementing finite element method with a dynamic-explicit code is an effective solution to observe the crushing process. A thin cylindrical structure found in aluminium can is modeled. A finite element impact simulation is then performed to observe the crushing process sequence and the stress and strain development history on axial impact employing IMPACT application program. An experimental of thin cylindrical structure on axial impact is conducted. The final crushing pattern after the impact is then compared with that from simulation. The result shows that final crushing pattern is in a good agreement with that shown in experiment. The stress and strain histories can be observed from the simulation.

SIF Evaluation Using XFEM and Line Spring Models Under High Strain Rate Environment for Leadfree Alloys

2011 ◽  
Author(s):  
Pradeep Lall ◽  
Mandar Kulkarni ◽  
Sandeep Shantaram ◽  
Jeff Suhling
Keyword(s):  
Stress Intensity Factor ◽  
Finite Element ◽  
Stress Intensity ◽  
Intensity Factor ◽  
High Strain Rate ◽  
Strain Rate ◽  
High Speed ◽  
High Strain ◽  
Strain Rates ◽  
Fracture Properties

In this paper, fracture properties of Sn3Ag0.5Cu leadfree high strain-rate solder-copper interface have been evaluated and validated with those from experimental methods. Bi-material Copper-Solder specimen have been tested at strain rates typical of shock and vibration with impact-hammer tensile testing machine. Models for crack initiation and propagation have been developed using Line spring method and extended finite element method (XFEM). Critical stress intensity factor for Sn3Ag0.5Cu solder-copper interface have been extracted from line spring models. Displacements and derivatives of displacements have been measured at crack tip and near interface of bi-material specimen using high speed imaging in conjunction with digital image correlation. Specimens have been tested at strain rates of 20s−1 and 55s−1 and the event is monitored using high speed data acquisition system as well as high speed cameras with frame rates in the neighborhood of 300,000 fps. Previously the authors have applied the technique of XFEM and DIC for predicting failure location and to develop constitutive models in leaded and few leadfree solder alloys [Lall 2010a]. The measured fracture properties have been applied to prediction of failure in ball-grid arrays subjected to high-g shock loading in the neighborhood of 12500g in JEDEC configuration. Prediction of fracture in board assemblies using explicit finite element full-field models of board assemblies under transient-shock is new. Stress intensity factor at Copper pad and bulk solder interface is also evaluated in ball grid array packages.

Investigation of the Impact Analysis of Microscale Thin-Walled Structures Manufactured by High-Speed Machining

2006 ◽  
Vol 326-328 ◽  
pp. 1599-1602
Author(s):  
Bo Sung Shin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Impact Analysis ◽  
Thin Wall ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Thin Walled Structures ◽  
Thin Walled ◽  
The Impact

High-speed machining (HSM) is very useful method as one of the most effective manufacturing processes because it has excellent quality and dimensional accuracy for precision machining. Recently micromachining technologies of various functional materials with very thin walls are needed in the field of electronics, mobile telecommunication and semiconductors. However, HSM is not suitable for microscale thin-walled structures because of the lack of their structure stiffness to resist high-speed cutting force. A microscale thin wall machined by HSM shows the characteristics of the impact behavior because the high-speed cutting force works very shortly on the machined surface. We propose impact analysis model in order to predict the limit thickness of a very thin-wall and investigate its limit thickness of thin-wall manufactured by HSM using finite element method. Also, in order to verify the usefulness of this method, we will compare finite element analyses with experimental results and demonstrate some applications.

Brain Deformation in Linear Head Impact

2009 ◽  
Author(s):  
Kaveh Laksari ◽  
Kurosh Darvish
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Single Point ◽  
Arbitrary Lagrangian Eulerian ◽  
Brain Deformation ◽  
Ale Formulation ◽  
Point Integration ◽  
Inertial Loading ◽  
Experimental Values ◽  
The Impact

In this study, a 2D model of the head underwent linear impact and the experiments were simulated by finite element models. A cylinder with a diameter of 100mm and height of 20mm was filled with 5% gelatin, which was used as the brain surrogate material. The physical model was mounted onto a High Speed Computer Controlled Impact System to generate inertial loading of approximately 50 G average deceleration. The deformation of the samples was studied through image processing. Finite element (FE) analysis was used to simulate the experiments. The impact tests were modeled with two methods: a Lagrangian formulation with single point integration and an Arbitrary Lagrangian Eulerian (ALE) formulation with single point integration and void using LS-Dyna FE code. In the model with slip contact, the normal and shear strains reached more than 20% in some regions, which confirmed the risk of axonal injury in the linear impacts applied in this study. It was seen that in the Lagrangian models, in order to stabilize the simulation, high bulk moduli needed to be used; however, this resulted in much smaller void generation in the posterior region of the model. It was shown that the void generation reaches the experimental values by introducing 1–2 mm initial gaps between brain and skull. The ALE model was more stable and less sensitive to the bulk modulus, but showed smaller deformations.

Study on the Orthogonal Cutting Process of Al7050T7451 with Uncoated and Coated Tools

2008 ◽  
Vol 392-394 ◽  
pp. 990-995 ◽  
Author(s):  
Hui Yue Dong ◽  
Pu Jin Huang ◽  
Y.B. Bi
Keyword(s):  
Finite Element ◽  
High Speed ◽  
High Strain ◽  
Bulk Material ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Machining Process ◽  
Workpiece Material ◽  
Coated Tool ◽  
The Impact

Tool wear during high speed machining process plays an important role in machining cost and efficiency. The purpose of this study is to examine the impact of tribological properties of coatings on cutting performance. Finite element methods (FEM) were used to model the effect of coated and uncoated cutting tools (K10) on the machinability of the aluminum alloy 7050T7451. Uncoated, Single coated, such as TiC, TiN and Al2O3 and multi-coated tool were studied. All finite element models were assumed to be plane strain. To achieve constitutive model of Al7050T7451 under conditions of machining that high strain rate, high strain and high temperature occur, high speed impact experiment and material drawing experiment were done. Comparison of FEM results shows that the highest temperatures in tools, the temperature change rates of different tools from surface to its bulk material, and the temperatures in chips are changed greatly. It also shows that the cutting temperature of coated tool is lower than uncoated tools, but cutting forces change very little. All these results show that coatings can be used to reduce adhesion between a tool and a workpiece material. The wear resistance of coated tool can be improved effectively and tool life is increased correspondingly.

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