scholarly journals FORMING PROCESS SIMULATION OF BIMETALLIC BILLET BY EXTRUSION FOR REW METHOD

2021 ◽  
Vol 27 (4) ◽  
pp. 210-213
Author(s):  
Alexander Schrek ◽  
Alena Brusilová ◽  
Pavol Sejč ◽  
Branislav Vanko
Keyword(s):  
Cross Section ◽  
Lap Joints ◽  
Outer Diameter ◽  
Ansys Software ◽  
Forming Process ◽  
Cold Forming ◽  
Forming Simulation ◽  
Resistance Element Welding ◽  
Extrusion Forming ◽  
Cross Section Geometry

The bimetallic joining elements were designed for lap joints of thin metallic (Fe-Fe, Fe-Al) as well as metallic – nonmetallic (Fe-PMMA, Al-PMMA) sheets by Resistance Element Welding (REW). The Cu tubes with an outer diameter of 4 mm, wall thickness of 0.5 mm, and a length of 11 mm filled with a solder Sn60Pb40 were used for the bimetallic joining elements producing. The required shape of joining elements is obtained by cold forming. Simulation by ANSYS software was chosen for the optimization of the forming process and geometry of functional parts of the forming tool allowing to use only one extrusion forming operation. The simulation results are stresses, strains, and modification of cross-section geometry of elements for the three proposed forming modes. The geometry of functional parts of the forming tool was compared with the results of cross-section macroanalysis of joining elements.

The Effect of Forming Speed on the Formability of a Zr-Based Bulk Metallic Glass

2015 ◽  
Vol 1088 ◽  
pp. 265-271 ◽  
Author(s):  
Wu Xiao ◽  
Jian Jun Li ◽  
Zhi Zhen Zheng ◽  
Jin Yang Li
Keyword(s):  
Metallic Glass ◽  
Bulk Metallic Glass ◽  
Wall Thickness ◽  
Supercooled Liquid ◽  
Supercooled Liquid Region ◽  
Outer Diameter ◽  
Liquid Region ◽  
Forming Process ◽  
Element Analysis ◽  
Extrusion Forming

Taking cup-shaped part (outer diameter D and wall thickness are chosen as 2.2 mm and 0.05 mm, respectively) as an example, the micro-back-extrusion forming process of a Zr55Cu30 Al10Ni5 bulk metallic glass (BMG) in its supercooled liquid region was studied by using finite-element analysis (FEM) and experiment. The effect of forming speed on the formability was analyzed based on the extrusion load, the rheological behavior of the material and the microstructure of the formed parts. It was found that while the forming speed is below than 4 μm/s, the extrusion load increases obviously with the increasing in forming speed, otherwise, the BMG will follow non-newtonian flow and the forming load is insensitive to the forming speed. The parts fabricated at 2 μm/s are obviously crystallized due to the long retention time of metallic glasses at high temperature, a higher forming speed is benefit to enhancing the formability if the BMG. On this basis, micro cup-shaped parts with only 0.05 mm in wall thickness are successfully extruded.

scholarly journals FEM analysis of manufacturing of a hollow product with an outer flange in a four-stage cold forming process

2021 ◽  
Vol 2130 (1) ◽  
pp. 012020
Author(s):  
Ł Wójcik ◽  
T Bulzak ◽  
G Winiarski
Keyword(s):  
Wall Thickness ◽  
Fem Analysis ◽  
Extrusion Process ◽  
Outer Diameter ◽  
Forming Process ◽  
Cold Forming ◽  
Hollow Shaft ◽  
Distribution Maps ◽  
Object A ◽  
Hollow Product

Abstract The paper presents the results of a FEM computer simulation of the cold forming process of a hollow sleeve forgings with an outer flange. Numerical simulations were carried out in DEFORM 2D / 3D. For the numerical calculations of the forming process the axisymmetric calculation module was used. As the test object, a tubular workpiece with an outer diameter of Ø50 mm and a wall thickness of 10 mm made of 42CrMo4 steel was used. The process of forming the rotary sleeve was conducted in four stages consisting of two technologies. The first stage of the research was the analysis and selection of parameters of the extrusion process, which was used for the first stage of forming. The processes of free extrusion and the use of a container were analysed. Furthermore different die angles and different wall thickness reductions were used. The products obtained in the extrusion process were upset in three conical blanks. The aim of the study was to analyse the numerical accuracy of the designed process of forming the hollow shaft with flange. The analysis of the results was based on the deformation intensity distribution maps, the Cockroft-Latham criterion distribution and the progress of the forming forces. On the basis of the conducted research, it was concluded that the presented process of forging a hollow product with a flange in four stages is possible to carry out correctly.

Conform—A New Concept for the Continuous Extrusion Forming of Metals

1974 ◽  
Vol 96 (3) ◽  
pp. 893-900 ◽  
Author(s):  
C. Etherington
Keyword(s):  
Cross Section ◽  
Future Development ◽  
Lead Wire ◽  
Forming Process ◽  
Laboratory Bench ◽  
Aluminium Wire ◽  
Continuous Extrusion ◽  
The Wire ◽  
Die Extrusion ◽  
Extrusion Forming

The paper describes a new continuous extrusion forming process, for metals, which is particularly applicable in the wire, section, and tube manufacturing fields. The principle of the process is based on the mechanical friction which exists between a billet and its container in conventional extrusion. If the container is rectangular in cross section and three sides are formed as a groove in a rotating wheel, with the fourth side forming a stationary shoe fitting against the outside of the wheel, then rotation of the wheel will carry the billet along with it. If a stop with die orifice is sized to fit the groove and is fixed to the shoe, then as the billet is forced against the die, extrusion can occur. The development of the process from a laboratory bench top model for lead wire, to a powered experimental machine capable of continuously extruding aluminium wire through ratios of 40:1 is described in the paper. The possibilities for future development are discussed and some guide is given to the possible size and capacities of projected machines.

Automated 3D measurement of fiber cross section morphology in handsheets

2012 ◽  
Vol 27 (2) ◽  
pp. 264-269 ◽  
Author(s):  
Christian Lorbach ◽  
Ulrich Hirn ◽  
Johannes Kritzinger ◽  
Wolfgang Bauer
Keyword(s):  
Image Analysis ◽  
Cross Section ◽  
Cross Sections ◽  
Image Plane ◽  
3D Measurement ◽  
Cross Sectional ◽  
Fiber Cross Section ◽  
Fiber Wall ◽  
Sectional Shape ◽  
Cross Section Geometry

Abstract We present a method for 3D measurement of fiber cross sectional morphology from handsheets. An automated procedure is used to acquire 3D datasets of fiber cross sectional images using an automated microtome and light microscopy. The fiber cross section geometry is extracted using digital image analysis. Simple sample preparation and highly automated image acquisition and image analysis are providing an efficient tool to analyze large samples. It is demonstrated that if fibers are tilted towards the image plane the images of fiber cross sections are always larger than the true fiber cross section geometry. In our analysis the tilting angles of the fibers to the image plane are measured. The resulting fiber cross sectional images are distorted to compensate the error due to fiber tilt, restoring the true fiber cross sectional shape. We use an approximated correction, the paper provides error estimates of the approximation. Measurement results for fiber wall thickness, fiber coarseness and fiber collapse are presented for one hardwood and one softwood pulp.

Grain Size Modification by Micro Rotary Swaging

2015 ◽  
Vol 651-653 ◽  
pp. 627-632 ◽  
Author(s):  
Svetlana Ishkina ◽  
Bernd Kuhfuss ◽  
Christian Schenck
Keyword(s):  
Grain Size ◽  
Longitudinal Section ◽  
Forming Process ◽  
Boundary Area ◽  
Cold Forming ◽  
Flat Surfaces ◽  
Rotary Swaging ◽  
2D Simulation ◽  
Physical Tests ◽  
Formed Part

Rotary swaging is a well established cold forming process e.g. in the automotive industry. In order to modify the material properties by swaging systematically, a new process of swaging with asymmetrical strokes of the forming dies is investigated. The newly developed tools feature flat surfaces and do not represent the geometry of the formed part as in conventional swaging. Numerical simulation and physical tests are carried out with special regard to the resulting geometry, mechanical properties and the microstructure. During these tests copper wires with diameter d0=1 mm are formed. Regarding the microstructure in the longitudinal section of formed specimens, elongation of grains in the central part and grain size reduction in the boundary area are observed. Furthermore, this approach opens up new possibilities to configure the geometry of wires. 2D-simulation is applied and discussed in the paper to investigate change of the processed geometry (cross-section) and shear strain distribution during the rotary swaging process.

Controlling the dynamic behavior of piezoceramic cylinders by cross-section geometry

2012 ◽  
Vol 223 (6) ◽  
pp. 1119-1136 ◽  
Author(s):  
Jan Awrejcewicz ◽  
Valeriy Storozhev ◽  
Vladimir Puzyrev
Keyword(s):  
Dynamic Behavior ◽  
Cross Section ◽  
Cross Section Geometry

Topology Optimization of Blank Geometry for the Sheet Forming Process

2012 ◽  
Author(s):  
Saber DorMohammadi ◽  
Mohammad Rouhi ◽  
Masoud Rais-Rohani
Keyword(s):  
Topology Optimization ◽  
Volume Fraction ◽  
Structural Response ◽  
Sheet Forming ◽  
Forming Process ◽  
Exchange Method ◽  
Forming Simulation ◽  
Blank Shape Optimization ◽  
Blank Shape ◽  
Consistent Subset

The newly developed element exchange method (EEM) for topology optimization is applied to the problem of blank shape optimization for the sheet-forming process. EEM uses a series of stochastic operations guided by the structural response of the model to switch solid and void elements in a given domain to minimize the objective function while maintaining the specified volume fraction. In application of EEM to blank optimization, a sheet forming simulation model is developed using Abaqus/Explicit. With the goal of minimizing the variability in wall thickness of the formed component, a subset of solid (i.e., high density) elements with the highest increase in thickness is exchanged with a consistent subset of void (i.e., low density) elements having the highest decrease in thickness so that the volume fraction remains constant. The EEM operations coupled with finite element simulations are repeated until the optimum blank geometry (i.e., boundary and initial thickness) is found. The developed numerical framework is applied to blank optimization of a benchmark problem. The results show that EEM is successful in generating the optimum blank geometry efficiently and accurately.

Piezoelectric T-Beam Microactuators

2008 ◽  
Author(s):  
Hareesh K. R. Kommepalli ◽  
Andrew D. Hirsh ◽  
Christopher D. Rahn ◽  
Srinivas A. Tadigadapa
Keyword(s):  
Cross Section ◽  
Fabrication Process ◽  
Mems Fabrication ◽  
Out Of Plane ◽  
Cantilevered Beam ◽  
Piezoelectric Mems ◽  
The Cross ◽  
T Beam ◽  
Cross Section Geometry

This paper introduces a novel T-beam actuator fabricated by a piezoelectric MEMS fabrication process. ICP-RIE etching from the front and back of a bulk PZT chip is used to produce stair stepped structures through the thickness with complex inplane shapes. Masked electrode deposition creates active and passive regions in the PZT structure. With a T-shaped crosssection, and bottom and top flange and web electrodes, a cantilevered beam can bend in-plane and out-of-plane with bimorph actuation in both directions. One of these T-beam actuators is fabricated and experimentally tested. An experimentally validated model predicts that the cross-section geometry can be optimized to produce higher displacement and blocking force.

Numerical Study of the Flow Forming Process of AISI 630 Stainless Steel

2011 ◽  
Vol 264-265 ◽  
pp. 24-29 ◽  
Author(s):  
Seyed Mohammad Ebrahimi ◽  
Seyed Ali Asghar Akbari Mousavi ◽  
Mostafa Soltan Bayazidi ◽  
Mohammad Mastoori
Keyword(s):  
Feeding Rate ◽  
Surface Defects ◽  
Numerical Study ◽  
Internal Diameter ◽  
The Finite Element Method ◽  
Forming Process ◽  
Flow Forming ◽  
Cold Forming ◽  
External Variables ◽  
Experimental Process

Flow forming is one of the cold forming process which is used for hollow symmetrical shapes. In this paper, the forward flow forming process is simulated using the finite element method and its results are compared with the experimental process. The variation of thickness of the sample is examined by the ultrasonic tests for the five locations of the tubes. To simulate the process, the ABAQUS explicit is used. The effects of flow forming variables such as the angle of rollers and rate of feeding of rollers, on the external variables such as internal diameter, thickness of tube and roller forces are considered. The study showed that the roller force and surface defects were reduced with low feeding rate and low rollers attack angles. Moreover, the sample internal diameter increased at low feeding rate and low rollers attack angles. The optimum variables for flow forming process were also obtained.

Sign in / Sign up

Export Citation Format

Share Document