Burr Minimization in Shaping of Aluminium Alloy-Through Experimental and Stress Analysis Approach

2011 ◽  
Vol 117-119 ◽  
pp. 1602-1605 ◽  
Author(s):  
Atanu Das ◽  
Partha Pratim Saha ◽  
Santanu Das
Keyword(s):  
Shear Stress ◽  
Aluminum Alloy ◽  
Aluminium Alloy ◽  
Equivalent Stress ◽  
Burr Formation ◽  
Angle Distribution ◽  
Great Problem ◽  
Maximum Equivalent Stress ◽  
Stress And Deformation ◽  
Exit Edge

Shaping Burrs are produced at the edge of a workpiece when a cutter exits it. It causes difficulties in manufacturing and assembly stages. Several attempts were made to minimize burr to suppress deburring to improve productivity. Deburring of the surface in shaping operation in railways industry and other industries is a great problem. An investigation on burr formation at the exit edge of aluminum alloy (4600-M) flats in shaping operation is done in this work under dry environment. It is found out that burr is negligible at 150 exit edge bevel angle. Distribution of shear stress is analyzed using FEM to validate the experimental results. It is found that maximum equivalent stress and deformation at different points on the 150 exit edge bevel angle become minimum justifying the experimental observation. Hence, an exit edge bevel of 150 may be adopted to have minimum burr formation.

Ship Performance Research Based on BP Neural Network

2014 ◽  
Vol 709 ◽  
pp. 176-179
Author(s):  
Han Liu ◽  
Fang Zhen Song ◽  
Ming Ming Li ◽  
Bo Song
Keyword(s):  
Neural Network ◽  
Shear Stress ◽  
Bp Neural Network ◽  
Optimization Design ◽  
Maximum Shear Stress ◽  
Equivalent Stress ◽  
Orthogonal Experimental Design ◽  
The Neural Network ◽  
Maximum Equivalent Stress ◽  
Ship Performance

The problem is solved that it is hard to provide analysis formulas about the maximum equivalent stress, the maximum shear stress and the structural geometric parameters for a ship. The finite element calculation is done with orthogonal experimental design under the most dangerous case. The data obtained are used as the training and test samples to establish BP neural network models of ship’s maximum equivalent stress and maximum shear stress. With the aid of Neural network toolbox in MATLAB, the topological structure of BP neural network mapping relationship between the whole ship performance indexes and design variables is established. The training and testing are completed with the data tested by the shipyard and the correctness of this network is verified. The neural network required for further optimization design is obtained. The neural network is helpful in reducing the ship mass without exceeding the allowable stress.

scholarly journals Influence of Circumferential Placement Position of Guide Vanes on Performance and Dynamic Characteristics of Nuclear Reactor Coolant Pump

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Xiaorui Cheng ◽  
Boru Lv ◽  
Chenying Ji ◽  
Ningning Jia ◽  
Dorah N
Keyword(s):  
Nuclear Reactor ◽  
Guide Vane ◽  
Equivalent Stress ◽  
Hydraulic Loss ◽  
Stress Strain ◽  
Coolant Pump ◽  
Guide Vanes ◽  
Reactor Coolant ◽  
Maximum Equivalent Stress ◽  
Exit Edge

In order to study the influence of the circumferential placement position of the guide vane on the flow field and stress-strain of a nuclear reactor coolant pump, the CAP1400 nuclear reactor coolant pump is taken as the research object. Based on numerical calculation and test results, the influence of circumferential placement position of the guide vane on the performance of the nuclear reactor coolant pump and stress-strain of guide vanes are analyzed by the unidirectional fluid-solid coupling method. The results show that the physical model and calculation method used in the study can accurately reflect the influence of the circumferential placement position of the guide vane on the nuclear reactor coolant pump. In the design condition, guide vane position has a great influence on the nuclear reactor coolant pump efficiency value, suction surface of the guide vane blade, and the maximum equivalent stress on the hub. However, it has a weak effect on the head value, pressure surface of the guide vane blade, and the maximum equivalent stress on the shroud. When the center line of the outlet diffuser channel of the case is located at the center of the outlet of flow channel of the guide vane, it is an optimal guide vane circumferential placement position, which can reduce the hydraulic loss of half of the case. Finally, it is found that the high stress concentration area is at the intersection of the exit edge of the vane blade and the front and rear cover, and the exit edge of the guide vane blade and its intersection with the front cover are areas where the strength damage is most likely to occur. This study provides a reference for nuclear reactor coolant pump installation, shock absorption design, and structural optimization.

A 3D Computation of Fluid-Structure Interaction in a Cyclone Separator

2014 ◽  
Vol 540 ◽  
pp. 106-109
Author(s):  
Pan Zhang ◽  
Bei Wang ◽  
Zhi Peng Guo ◽  
Ya Nan Shen
Keyword(s):  
Equivalent Stress ◽  
Fluid Structure Interaction ◽  
Cyclone Separator ◽  
The Finite Element Method ◽  
Gas Velocity ◽  
Fluid Structure ◽  
Structure Interaction ◽  
Maximum Equivalent Stress ◽  
Stress And Deformation ◽  
Volume Method

This work presents a 3D computation of fluid-structure interaction in a cyclone separator. The finite volume method was used to simulate the flow field in the cyclone separator. The fluid-structure interaction was conducted by transferring the computational pressure distribution to the corresponding surface of the cyclone shell. The stress and deformation distribution in the cyclone shell was computed by the finite element method. Results obtained show that the maximum equivalent stress and deformation is linearly increases with the increases of the inlet gas velocity.

scholarly journals Numerical Analysis of Blade Stress of Marine Propellers

2020 ◽  
Vol 19 (3) ◽  
pp. 436-443
Author(s):  
Kai Yu ◽  
Peikai Yan ◽  
Jian Hu
Keyword(s):  
Axial Strain ◽  
Equivalent Stress ◽  
Open Water ◽  
Object A ◽  
Marine Propellers ◽  
Maximum Equivalent Stress ◽  
Tip Position ◽  
Stress And Deformation ◽  
Open Water Performance ◽  
Set Up

Abstract In this study, a series of numerical calculations are carried out in ANSYS Workbench based on the unidirectional fluid–solid coupling theory. Using the DTMB 4119 propeller as the research object, a numerical simulation is set up to analyze the open water performance of the propeller, and the equivalent stress distribution of the propeller acting in the flow field and the axial strain of the blade are analyzed. The results show that FLUENT calculations can provide accurate and reliable calculations of the hydrodynamic load for the propeller structure. The maximum equivalent stress was observed in the blade near the hub, and the tip position of the blade had the largest stress. With the increase in speed, the stress and deformation showed a decreasing trend.

scholarly journals Finite Element Modeling of Residual Stress at Joint Interface of Titanium Alloy and 17-4PH Stainless Steel

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 629
Author(s):  
Nana Kwabena Adomako ◽  
Sung Hoon Kim ◽  
Ji Hong Yoon ◽  
Se-Hwan Lee ◽  
Jeoung Han Kim
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Finite Element Modeling ◽  
Equivalent Stress ◽  
Stress Gradient ◽  
Joint Interface ◽  
Element Modeling ◽  
Actual Experiment ◽  
Maximum Equivalent Stress

Residual stress is a crucial element in determining the integrity of parts and lifetime of additively manufactured structures. In stainless steel and Ti-6Al-4V fabricated joints, residual stress causes cracking and delamination of the brittle intermetallic joint interface. Knowledge of the degree of residual stress at the joint interface is, therefore, important; however, the available information is limited owing to the joint’s brittle nature and its high failure susceptibility. In this study, the residual stress distribution during the deposition of 17-4PH stainless steel on Ti-6Al-4V alloy was predicted using Simufact additive software based on the finite element modeling technique. A sharp stress gradient was revealed at the joint interface, with compressive stress on the Ti-6Al-4V side and tensile stress on the 17-4PH side. This distribution is attributed to the large difference in the coefficients of thermal expansion of the two metals. The 17-4PH side exhibited maximum equivalent stress of 500 MPa, which was twice that of the Ti-6Al-4V side (240 MPa). This showed good correlation with the thermal residual stress calculations of the alloys. The thermal history predicted via simulation at the joint interface was within the temperature range of 368–477 °C and was highly congruent with that obtained in the actual experiment, approximately 300–450 °C. In the actual experiment, joint delamination occurred, ascribable to the residual stress accumulation and multiple additive manufacturing (AM) thermal cycles on the brittle FeTi and Fe2Ti intermetallic joint interface. The build deflected to the side at an angle of 0.708° after the simulation. This study could serve as a valid reference for engineers to understand the residual stress development in 17-4PH and Ti-6Al-4V joints fabricated with AM.

Research on Springback Compensation of Aluminium Alloy Automobile Body Panel

2013 ◽  
Vol 791-793 ◽  
pp. 390-393
Author(s):  
Lei Hu ◽  
Hui Xie ◽  
Xing Xing Hu ◽  
Zhi Hong Pan ◽  
Hao Ming Jiang ◽  
...  
Keyword(s):  
Crystal Structure ◽  
Aluminum Alloy ◽  
Aluminium Alloy ◽  
Curved Surface ◽  
Practical Application ◽  
Springback Compensation ◽  
Cycle Simulation ◽  
Automobile Body ◽  
Compensation Principle ◽  
Working Procedure

The performance of the aluminum alloy makes it the most popular lightweight materials for the automobile manufacturers. However, due to the disparity on the crystal structure,it has the higher springback values compared with steel. In order to solve the problem, we put forward a new springback compensation method based on displacement compensation principle and the principle of curved surface fairing design methods. Though full cycle simulation and calculate springback value for each working procedure, then generate the springback compensation surface. The methods practical application effect is good.

scholarly journals Numerical Simulation and Experimental Study on Axial Stiffness and Stress Deformation of the Braided Corrugated Hose

2021 ◽  
Vol 11 (10) ◽  
pp. 4709
Author(s):  
Dacheng Huang ◽  
Jianrun Zhang
Keyword(s):  
Numerical Simulation ◽  
Geometric Model ◽  
Equivalent Stress ◽  
Element Model ◽  
Maximum Error ◽  
Structural Features ◽  
Axial Stiffness ◽  
Frictional Stress ◽  
Maximum Equivalent Stress ◽  
Simulation Results

To explore the mechanical properties of the braided corrugated hose, the space curve parametric equation of the braided tube is deduced, specific to the structural features of the braided tube. On this basis, the equivalent braided tube model is proposed based on the same axial stiffness in order to improve the calculational efficiency. The geometric model and the Finite Element Model of the DN25 braided corrugated hose is established. The numerical simulation results are analyzed, and the distribution of the equivalent stress and frictional stress is discussed. The maximum equivalent stress of the braided corrugated hose occurs at the braided tube, with the value of 903MPa. The maximum equivalent stress of the bellows occurs at the area in contact with the braided tube, with the value of 314MPa. The maximum frictional stress between the bellows and the braided tube is 88.46MPa. The tensile experiment of the DN25 braided corrugated hose is performed. The simulation results are in good agreement with test data, with a maximum error of 9.4%, verifying the rationality of the model. The study is helpful to the research of the axial stiffness of the braided corrugated hose and provides the base for wear and life studies on the braided corrugated hose.

Study on the Formability of Aluminium Alloy Sheets at Room and Elevated Temperatures

2016 ◽  
Vol 877 ◽  
pp. 393-399
Author(s):  
Jia Zhou ◽  
Jun Ping Zhang ◽  
Ming Tu Ma
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Elevated Temperature ◽  
Aluminium Alloy ◽  
Aluminium Alloys ◽  
Elevated Temperatures ◽  
Hot Stamping ◽  
Natural Aging ◽  
Alloy Sheet ◽  
Aluminum Alloy Sheet

This paper presents the main achievements of a research project aimed at investigating the applicability of the hot stamping technology to non heat treatable aluminium alloys of the 5052 H32 and heat treatable aluminium alloys of the 6016 T4P after six months natural aging. The formability and mechanical properties of 5052 H32 and 6016 T4P aluminum alloy sheets after six months natural aging under different temperature conditions were studied, the processing characteristics and potential of the two aluminium alloy at room and elevated temperature were investigated. The results indicated that the 6016 aluminum alloy sheet exhibit better mechanical properties at room temperature. 5052 H32 aluminum alloy sheet shows better formability at elevated temperature, and it has higher potential to increase formability by raising the temperature.

Researches on Burr Formation in Milling Al-Alloy

2010 ◽  
Vol 135 ◽  
pp. 164-169 ◽  
Author(s):  
Ming Chen ◽  
Bin Rong ◽  
Gang Liu
Keyword(s):  
Aluminum Alloy ◽  
Parameter Optimization ◽  
Tool Path ◽  
Burr Formation ◽  
Al Alloy ◽  
Active Process ◽  
Processing Parameter ◽  
Tool Path Planning ◽  
Rough Machining ◽  
Manufacturing Automation

Burr formation is a bottleneck of the production line and deteriorates the automation integrity. To this question, investigations were carried out in this paper on the burr formation in milling aluminum alloy (Al-alloy), in order to enhance productivity and workpiece quality by active process control. Milling burr formation were predicted and minimized for the sake of rough machining and finishing operation, using strategies of tool path planning, processing parameter optimization as well as workpiece rigidity strengthening. The conclusions reached in this paper are useful in practice to realize burr-free Al-alloy milling for manufacturing automation.

Design Optimization for Fir-Tree Root of Turbine Blade Considering Manufacturing Variations

2013 ◽  
Vol 694-697 ◽  
pp. 2733-2737
Author(s):  
Qin Zhou ◽  
Ming Hui Zhang ◽  
Hui Yong Chen ◽  
Yong Hui Xie
Keyword(s):  
Particle Swarm Optimization ◽  
Turbine Blade ◽  
Equivalent Stress ◽  
Particle Swarm ◽  
Pattern Search ◽  
Design System ◽  
Contact Method ◽  
Swarm Optimization ◽  
Maximum Equivalent Stress ◽  
Manufacturing Variation

An optimization design system for fir-tree root of turbine blade has been developed in this paper. In the system, a parametric model of the blade and rim was established based on the parametric design language APDL, and nonlinear contact method was used for analysis by ANSYS, meanwhile some optimization algorithms, such as Pattern Search Algorithm, Genetic Algorithm, Simulated Annealing Algorithm and Particle Swarm Optimization, were adopted to control the optimizing process. Five cases of manufacturing variation in contact surfaces between root and rim were taken into account, and the design objective was to minimize the maximum equivalent stress of root-rim by optimizing eight critical geometrical dimensions of the root and rim. As a result, the maximum equivalent stress of root-rim decreases markedly after the optimization in all cases. In consideration of both precision and computing time, particle swarm optimization is assessed as the best algorithm to solve structure optimization problem in this work. Corresponding to five different cases of manufacturing variation, the maximum equivalent stress of root and rim reduces by 7%, 8%; 27%, 24%; 27%, 22%; 25%, 19%; 10%, 14% using the Particle Swarm Optimization.

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