Numerical Investigation of Fine Blanking of a Helical Gear

2012 ◽  
Vol 190-191 ◽  
pp. 121-125 ◽  
Author(s):  
Shan Yang ◽  
Lin Hua ◽  
Yan Li Song
Keyword(s):  
Effective Strain ◽  
Metal Flow ◽  
Three Dimensional ◽  
Helical Gear ◽  
Fe Model ◽  
Forming Process ◽  
Rigid Plastic ◽  
Fine Blanking ◽  
Metal Forming Process ◽  
Blanking Process

Fine blanking, as an effective and economy metal forming process, can be used for the manufacturing of helical gears with inclined forming movement. In the present study, a reliable three-dimensional (3D) rigid-plastic finite element (FE) model is developed on the DEFORM-3D platform for rotational fine blanking of a helical gear. Based on this FE model, distributions of different field variables such as metal flow velocity, mean stress and effective strain are obtained, and cut surface features and punch stroke curve are predicted. The results achieved in this study can not only evaluate the capabilities of the rotational fine blanking process of a helical gear, but also provide valuable guidelines and a better understanding of the deformation mechanism of this process.

Intermediate Slabs and Optimization in Forging Process of Balance Elbow by FEM

2014 ◽  
Vol 721 ◽  
pp. 127-130
Author(s):  
Bo Jun Xiong ◽  
Ke Lu Wang ◽  
Jun Fang ◽  
Yun Huang
Keyword(s):  
Temperature Distribution ◽  
Strain Distribution ◽  
Simulation Analysis ◽  
Effective Strain ◽  
Maximum Load ◽  
Load Force ◽  
Fe Model ◽  
Forming Process ◽  
Rigid Plastic ◽  
Forging Process

Based on Deform-3D software, a 3D rigid-plastic FE model of forging forming process was established, then simulation analysis effective strain distribution, temperature distribution and load-stroke curve of three kinds of intermediate slabs (S1,S2,S3) in forging process. The results show that the optimized intermediate slab (S3) of effective strain distribution and temperature distribution is most homogeneous. And the maximum load force is minimum, the Shapes and dimensions of forging reach the preset value.

scholarly journals Analysis Of Deformation And Microstructural Evolution In The Hot Forging Of The Ti-6Al-4V Alloy

2015 ◽  
Vol 60 (2) ◽  
pp. 597-604 ◽  
Author(s):  
M. Kukuryk
Keyword(s):  
Effective Strain ◽  
Metal Flow ◽  
Hot Forging ◽  
Three Dimensional ◽  
Test Results ◽  
Rigid Plastic ◽  
Microstructure Parameters ◽  
Thermal Phenomena ◽  
Tool Types

Abstract The paper presents the analysis of the three-dimensional strain state for the cogging process of the Ti-6Al-4V alloy using the finite element method, assuming the rigid-plastic model of the deformed body. It reports the results of simulation studies on the metal flow pattern and thermal phenomena occurring in the hot cogging process conducted on three tool types. The computation results enable the determination of the distribution of effective strain, effective stress, mean stress and temperature within the volume of the blank. This solution has been complemented by adding the model of microstructure evolution during the cogging process. The numerical analysis was made using the DEFORM-3D consisting of a mechanical, a thermal and a microstructural parts. The comparison of the theoretical study and experimental test results indicates a potential for the developed model to be employed for predicting deformations and microstructure parameters.

scholarly journals Analysis Of Deformation And Microstructural Evolution In The Hot Forgingof The Ti-6Al-4V Alloy

2015 ◽  
Vol 60 (3) ◽  
pp. 1639-1648 ◽  
Author(s):  
M. Kukuryk
Keyword(s):  
Effective Strain ◽  
Metal Flow ◽  
Three Dimensional ◽  
Test Results ◽  
The Finite Element Method ◽  
Rigid Plastic ◽  
Microstructure Parameters ◽  
Thermal Phenomena ◽  
Tool Types

Abstract The paper presents the analysis of the three-dimensional strain state for the cogging process of the Ti-6Al-4V alloy using the finite element method, assuming the rigid-plastic model of the deformed body. It reports the results of simulation studies on the metal flow pattern and thermal phenomena occurring in the hot cogging process conducted on three tool types. The computation results enable the determination of the distribution of effective strain, effective stress, mean stress and temperature within the volume of the blank. This solution has been complemented by adding the model of microstructure evolution during the cogging process. The numerical analysis was made using the DEFORM-3D consisting of a mechanical, a thermal and a microstructural parts. The comparison of the theoretical study and experimental test results indicates a potential for the developed model to be employed for predicting deformations and microstructure parameters.

Numerical Study on the Comparison of Deformation Characteristics during the Fine Blanking Process of Spur Gears and Helical Gear

2015 ◽  
Vol 639 ◽  
pp. 559-566 ◽  
Author(s):  
Wen Ting Xia ◽  
Hua Jie Mao ◽  
Lin Hua ◽  
Yan Xiong Liu
Keyword(s):  
Production Efficiency ◽  
Numerical Study ◽  
Numerical Models ◽  
Spur Gears ◽  
Deformation Characteristics ◽  
Forming Process ◽  
Rigid Plastic ◽  
Fine Blanking ◽  
Helical Gears ◽  
Blanking Process

As important transmission components, helical gears have been widely applied to mechanical and automotive fields. The traditional manufacturing process for helical gears is machining, which is time-consuming and result in the high cost of gears. In order to improve the production efficiency and product quality of helical gears, a novel forming process principle for the fine blanking of helical gears was developed. In this study, reliable three-dimensional (3D) rigid-plastic finite element (FE) models of single tooth and complete gears were set up and investigated using the software Deform-3D, the deformation characteristics of fine blanking of spur gears and helical gears were compared. Based on the valid numerical models, variation tendency of different field variables such as damage material flow velocity, and mean stress were obtained, as well as the feature of the tooth section, which provides a better understanding of the deformation mechanism of rotational fine blanking process.

Finite Element Predictions for a Cold Sheet Metal Forming Process Using Tetrahedral Mini-Elements

2011 ◽  
Author(s):  
Min-Cheol Lee ◽  
Sang-Hyun Sim ◽  
Jae-Gun Eom ◽  
Man-Soo Joun ◽  
Wan-Jin Chung
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Thickness Variation ◽  
Forming Process ◽  
Rigid Plastic ◽  
Element Mesh ◽  
Metal Forming Process

In this paper, finite element prediction of a cold sheet metal forming process is investigated using solid elements. A three-dimensional rigid-plastic finite element method with conventional linear tetrahedral MINI-elements [1, 2] is employed. This technique has traditionally been used for bulk metal forming simulations. Both single- and double-layer finite element mesh systems are studied, with particular attention to their effect on the deformed shape of the workpiece and thickness variation. The procedure is applied to the well-known problem of the NUMISHEET93 international benchmark. The resulting predictions are compared with experimental observations found in the literature, and good agreement is noted.

Investigation into Bicycle Front Fork Forming Process of Simulation and Experiment

2014 ◽  
Vol 626 ◽  
pp. 199-204
Author(s):  
Dyi Cheng Chen ◽  
Wen Hsuan Ku
Keyword(s):  
Finite Element ◽  
Effective Strain ◽  
Three Dimensional ◽  
Forming Process ◽  
Rigid Plastic ◽  
Billet Temperature ◽  
Finite Element Software ◽  
Plastic Deformation Behavior ◽  
Graphics Software ◽  
Three Dimensional Finite Element

This study uses the three dimensional finite element code to examine the plastic deformation behavior of bicycle front fork forging. First the paper used Solid works 2010 3D graphics software to design the bicycle front fork die, and that used rigid-plastic model finite element analytical methods, and assuming mode to be rigid body. The front fork material is titanium alloy Ti-6Al-4V. A series of simulation analyses in which the variables depend on die temperature, billet temperature, forging speed, friction factors, die angle are reveal to effective stress, effective strain, die radial load distribution and damage value for bicycle front fork forming. The simulation combined Taguchi method to analysis optimization. The results of the analysis can be used to stabilize finite element software to forming front fork, and also confirm the suitability of bicycle front fork through experiment optimization.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

FEM Simulation Analysis of Cross Wedge Rolling Process

2011 ◽  
Vol 381 ◽  
pp. 72-75
Author(s):  
Bin Li
Keyword(s):  
Simulation Analysis ◽  
Three Dimensional ◽  
Fem Simulation ◽  
Rolling Process ◽  
Stress Distributions ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Pressure Distributions ◽  
Metal Forming Process ◽  
Rolling Load

This paper investigates the interfacial slip between the forming tool and workpiece in a relatively new metal forming process, cross-wedge rolling. Based on the finite elements method, three-dimensional mechanical model of cross wedge rolling process has been developed. Examples of numerical simulation for strain, stress distributions and rolling load components have been included. The main advantages of the finite element method are: the capability of obtaining detailed solutions of the mechanics in a deforming body, namely, stresses, shapes, strains or contact pressure distributions; and the computer codes, can be used for a large variety of problems by simply changing the input data.

scholarly journals A Novel Force Variation Fine Blanking Process for the High-strength and Low-plasticity Material

2021 ◽  
Author(s):  
Huajie Mao ◽  
Han Chen ◽  
Yanxiong Liu ◽  
Kaisheng Ji
Keyword(s):  
Early Stage ◽  
Hydrostatic Stress ◽  
High Strength ◽  
Forming Force ◽  
Forming Process ◽  
Fine Blanking ◽  
Application Range ◽  
Cutting Surface ◽  
Force Variation ◽  
Blanking Process

Abstract Fine blanking is a kind of metal forming process with the advantages of high precision, good surface quality and low cost. Influenced by the concept of lightweight, a large number of metal materials with high strength are widely used in various fields. High strength materials are prone to be cracked during plastic deformation due to their poor plasticity, which limits the application range of them. This paper proposed a force variation fine blanking process for high-strength and low-plasticity materials. At the same time, a method to find the curve of forming force for this novel process was presented. A 2D finite element fine blanking model was established for the TC4 material. Combining genetic algorithm and neural network methods, a model was built up to find the optimal forming force loading curve. The parts fabricated by force variation loading and constant loading fine blanking process were compared through experiments. The mechanism of force variation fine blanking is also revealed. The forming force mainly affects the length of clean cutting surface by affecting hydrostatic stress. According to the ultimate optimal loading curve, the forming force should be kept at a low level in the early stage of blanking stroke, and increased gradually in the ending stage. In the application of force variation fine blanking, the part with long length of clean cutting surface can be obtained with lower die load.

Metal Forming With Laser Origami: Parameter Analysis and Optimization

2020 ◽  
Author(s):  
Peiwen J. Ma ◽  
Yue Hao ◽  
Jyh-Ming Lien ◽  
Edwin A. Peraza Hernandez
Keyword(s):  
Metal Forming ◽  
Search Algorithm ◽  
Minimum Energy ◽  
Three Dimensional ◽  
Parameter Analysis ◽  
Forming Process ◽  
Polygonal Mesh ◽  
Target Shape ◽  
Material Usage ◽  
Metal Forming Process

Abstract Laser origami is a metal forming process where an initially planar sheet is transformed into a target three-dimensional (3D) form through cutting and folding operations executed by a laser beam. A key challenge in laser origami is to determine the locations of the cuts and folds required to transform the planar sheet into the 3D target shape. The region of the planar sheet that can be transformed into the target shape through these cuts and folds is denoted as the net. This paper presents a method to determine optimal net(s) for laser origami based on criteria including minimum energy usage, minimum fabrication time, minimum error in the fold angles, and minimum material usage. The 3D target shape is given as a polygonal mesh. To generate a net, each edge in the mesh must be classified as a cut or a fold. The energy, time, and other parameters associated with cutting or folding each edge are determined using experimentally calibrated formulas. A search algorithm is subsequently implemented to find combinations of cut and folded edges that provide an optimal set of nets for the given 3D target shape based on a cost function. Nets that are disconnected or have overlapping regions are discarded since they are invalid for laser origami. The method is demonstrated by applying it to different target shapes and cost functions.

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