scholarly journals Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance

Polymers ◽  
2020 ◽  
Vol 12 (12) ◽  
pp. 2801
Author(s):  
Lorenzo Sisca ◽  
Patrizio Tiziano Locatelli Quacchia ◽  
Alessandro Messana ◽  
Andrea Giancarlo Airale ◽  
Alessandro Ferraris ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Composite Materials ◽  
Research Work ◽  
Thickness Variation ◽  
Forming Process ◽  
Element Analysis ◽  
Mapping Tool ◽  
The Press ◽  
Thermoforming Process ◽  
Thermosetting Composite

This research work investigated the influence of the press molding manufacturing process on the mechanical properties, both for thermoplastic and thermosetting fiber reinforced composite materials. The particular geometry of the case study, called Double Dome, was considered in order to verify the behavior of the Thermoplastic and Thermosetting prepreg in terms of shell thickness variation and fibers shear angle evolution during the thermoforming process. The thermoforming simulation was performed using LS-DYNA® Finite Element Analysis (FEA) code, and the results were transferred by Envyo®, a dedicated mapping tool, into a LS-DYNA® virtual model for the structural simulation. A series of Double Dome specimens was produced with industrial equipment, and a bending experimental test was been carried on. Finally, a numerical-experimental correlation was performed, highlighting a significant forecast of the mechanical properties for the considered component.

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

Joining sheets made from dissimilar materials by hole hemming

2022 ◽  
pp. 146442072110726
Author(s):  
Mohammad Mehdi Kasaei ◽  
Lucas FM da Silva
Keyword(s):  
Mechanical Properties ◽  
Research Work ◽  
Dissimilar Materials ◽  
Element Analysis ◽  
Lightweight Structures ◽  
Lap Shear ◽  
Gradual Failure ◽  
Peel Tests ◽  
Dp780 Steel ◽  
Joining Process

This research work presents a new joining process based on the hemming process for attaching sheets made from dissimilar materials with very different mechanical properties. The process is termed ‘hole hemming’ and consists in producing a mechanical interlock between pre-drilled holes which can be made anywhere on the sheets. The process is carried out in a two-stage operation including flanging the hole of an outer sheet and bending the flange over the hole of an inner sheet. First, the joining stages and the required tools are designed. Then, the joining of DP780 steel and AA6061-T6 aluminium alloy sheets, which are applied to manufacture lightweight structures in the automotive industries, is investigated using finite element analysis. Results show that the hole hemming process is able to successfully join these materials without fracture. The hole-hemmed joint withstood the maximum forces of 2.5 and 0.5 kN in single-lap shear and peel tests, respectively, and failed with hole bearing mode which is known as a gradual failure mode. The results demonstrate the applicability of the hole hemming process for joining dissimilar materials.

scholarly journals Investigating of Mechanical Behavior of AA5083 in the Pressing Process Using Finite Element Analysis

2017 ◽  
Vol 11 (9) ◽  
pp. 51
Author(s):  
Babak Beglarzadeh ◽  
Behnam Davoodi
Keyword(s):  
Mechanical Properties ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Stress ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Forming ◽  
Aluminum Alloy 5083 ◽  
And Control

The process of cold forming is considered of the most different industries and the use of such process in the manufacture of components and small parts has expanded. Therefore, analyzing the behavior of metals in this process to identify and control durability that is the main factor of limiting process has particular importance in industrial forming processes. In this study, cold forming process of aluminum metal has been studied and its effect on its mechanical properties has been evaluated. For this purpose, first modeling piece of aluminum alloy 5083 for cold forming process is carried out and using finite element analysis, mechanical properties of considered piece during cold forming processes are investigated. The results show that by reducing friction, stress and strain during the process will reduce, thereby durability of the piece increases, or in other words, ductile fracture occurs in longer life and higher stresses. The results show that by proper forming operations, it can be improved the strength and durability of aluminum alloy. Finally, validation of results, by comparing simulation results with experimental results is carried out.

Finite element analysis of the press forming process

2017 ◽  
Vol 131-132 ◽  
pp. 767-775 ◽  
Author(s):  
Muhammad Awais ◽  
Joonas Sorvari ◽  
Panu Tanninen ◽  
Teemu Leppänen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Forming Process ◽  
Element Analysis ◽  
Press Forming ◽  
The Press

Evaluating the Mechanical Properties of 3D Woven Carbon-Epoxy Composite Materials Using Experimental Data and FEA Methods

2011 ◽  
Author(s):  
Mahdi Farahikia ◽  
Sunilbhai Macwan ◽  
Fereidoon Delfanian ◽  
Zhong Hu
Keyword(s):  
Experimental Data ◽  
Mechanical Properties ◽  
Composite Materials ◽  
Epoxy Composite ◽  
External Pressure ◽  
Fiber Direction ◽  
Strain Gages ◽  
Element Analysis ◽  
Test Specifications ◽  
Dog Bone

A series of tensile, compression and shear tests were carried out on carbon-epoxy composite materials to evaluate their mechanical properties. The experiments were set upin accordance with ASTM standards that best corresponded to the test specifications. Specimens were categorized into groups according to their dimensions and shape. Based on testing requirements, some were cut into rectangular and others into dog bone specimens to determine the effects of stress concentration. A number of specimens were reinforced at both ends by means of tabs which were bonded on both faces to reduce the effects of the external pressure exerted on them through the grips of the testing machines, and the rest of them were tested without any reinforcement tabs. All the specimens were tested until failure. Load, elongation (displacement) and strain data were recorded by means of strain gages and data acquisition systems. The experimental results obtained from similar tests on different groups are compared to examine the conformity of the results regardless of dimension and geometry, and are also verified by Finite Element Analysis (FEA). In addition, FEA is used to study different conditions, such as geometry, that could affect the final results. The experimental data are analyzed and effects of fiber direction on failure method are studied. It was concluded that shape and geometry factors as well as fiber direction influenced the failure method. The work, however, is still in progress and tests under conditions, such as elevated temperature, will be conducted to study other effects on the mechanical properties of 3D woven carbon-epoxy composites.

scholarly journals Finite Element Analysis of Ply Orientation Effect on Mechanical Properties of Hybrid Composite Material

2021 ◽  
Author(s):  
Mahesh Gund ◽  
R T Vyavahare
Keyword(s):  
Mechanical Properties ◽  
Composite Material ◽  
Carbon Fiber ◽  
Low Cost ◽  
Research Work ◽  
Natural Fibers ◽  
Weight Ratio ◽  
Coir Fiber ◽  
Banana Plant ◽  
Element Analysis

In recent years, composite material is used as an alternative material for materials like metal, wood, etc. due to low in weight, strength to weight ratio and stiffness properties. Natural fibers like coir fiber, palm fiber, jute fiber, banana plant fiber, etc have low cost, easy availability and less harmful to human body. Also, carbon fiber having various properties such as high strength to weight ratio, rigidity, good tensile strength, fatigue resistance, fire resistance/not flammable, high thermal conductivity. This research work aims to find out the mechanical properties of Carbon fiber, Coir fiber and Epoxy composite material with different ply orientations angles by using FEA software Ansys APDL R15.0.

Characterisation and Object-Oriented Finite Element Modelling of Polypropylene/ Organoclay Nanocomposites

2007 ◽  
Vol 334-335 ◽  
pp. 841-844 ◽  
Author(s):  
Y. Dong ◽  
Debes Bhattacharyya ◽  
P.J. Hunter
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Numerical Modelling ◽  
Computational Models ◽  
Research Work ◽  
Weight Ratio ◽  
Object Oriented ◽  
Mechanical Analysis ◽  
Element Analysis ◽  
Maleated Polypropylene

Although much research work has been conducted on the production and characterisation of polypropylene/organoclay nanocomposites, the effects of nanoscale fillers with respect to actual morphology through numerical modelling have been rarely addressed. This paper describes a unique development from fabrication and experimental characterisation to the numerical modelling of polypropylene/organoclay nanocomposites based on the real mapping of nano/microstructures. Twin screw extrusion is used with a two-step masterbatch compounding method to prepare such nanocomposites with organoclays (ranging between 1wt% and 10wt%) and maleated polypropylene (1:1 weight ratio). The material characterisation using X-ray diffraction (XRD), scanning electron microscopy (SEM) and dynamic mechanical analysis (DMTA) are conducted and mechanical properties are determined by tensile, flexural and impact tests. Finally, computational models are established by using an innovative object-oriented finite element analysis code (OOF) to predict the overall mechanical properties of nanocomposites.

Finite Element Analysis for the Roll Forming Process of Rib

2018 ◽  
Vol 878 ◽  
pp. 302-307
Author(s):  
Dong Won Jung
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Equivalent Plastic Strain ◽  
Von Mises Stress ◽  
Roll Forming ◽  
Thickness Variation ◽  
Forming Process ◽  
Element Analysis ◽  
High Production Rate ◽  
Roll Forming Process

Roll forming is a continuous profile production process to form sheet metal progressively into the desired shape with closer tolerances. The process offers several advantages such as complex geometrical shapes, high strength, dimensional accuracy, closer tolerances, better quality and consistency, high production rate, improved conformity, and good surface finish. Several parts of automobile body are produced with this process. Nowadays roll forming technology draws more attentions than before in the automotive industry. In this paper, A Finite Element Method applied to study von mises stress, equivalent plastic strain, thickness, plastic strain, longitudinal strain and spring back of the metal sheet with ribs formed by roll forming process. The thickness variation was almost -6.144%.

Measurement of Mechanical Properties on Line Pipe: Comparison of Different Methodologies

2014 ◽  
Author(s):  
Steven Cooreman ◽  
Dennis Van Hoecke ◽  
Martin Liebeherr ◽  
Philippe Thibaux ◽  
Mary Yamaguti Enderlin
Keyword(s):  
Mechanical Properties ◽  
Yield Strength ◽  
Tensile Tests ◽  
Ring Expansion ◽  
Isotropic Hardening ◽  
Forming Process ◽  
Element Analysis ◽  
Line Pipe ◽  
Expansion Test ◽  
Round Bar

Line pipe manufacturers always have to verify the mechanical properties on pipe to make sure that the pipe meets the requirements specified by the standard and/or customer. This involves measurement of mechanical properties along the hoop direction. The most accurate way to do so is by performing a ring expansion test, which, however, requires dedicated tools. The two other methodologies consist of standard tensile tests on either non-flattened round bar samples or so called ‘flattened tensile samples’. Round bar samples have the disadvantage that only part of the pipe’s wall thickness is considered. Furthermore they can only be used in case of larger OD/t ratios. Tests on flattened samples, on the other hand, require a flattening operation, which induces additional plastic deformation. However, this flattening operation is not standardized. Moreover, it was observed that the mechanical properties — especially the yield strength — resulting from tensile tests on flattened samples largely depend on test parameters such as residual deflection, extensometer position, flattening procedure, etc. Most manufacturers prefer to test flattened samples, because sample preparation is straightforward and cheap. Moreover it only requires a standard tensile bench. An extensive FEA (Finite Element Analysis) study was launched to investigate the influence of those parameters on the measured yield strength. The applied FEA methodology consists of three steps. First the complete pipe forming process is modeled (in a simplified way). Next a pipe sample is flattened. Finally a tensile sample is cut from the flattened pipe sample and loaded in tension. The mechanical material behaviour is described by a combined kinematic-isotropic hardening model, which allows taking into account the Bauschinger effect. The results are also compared to simulations of ring expansion tests and tests on round bar samples. Next a dedicated experimental test campaign was performed to verify the results of FEA. Results of ring expansion tests are compared to results obtained on round bar samples and flattened tensile samples. The results of this study have shown that the applied methodology significantly affects the measured yield strength. Moreover tests on insufficiently flattened samples could considerably underestimate the actual yield strength on pipe. Finally some guidelines are provided to improve the reproducibility of the measured yield strength when using flattened samples.

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