Influence of Punch Velocity and Strength Matching on the Quality of SPR with Half-Hollow Rivet Based Numerical Simulation

2013 ◽  
Vol 319 ◽  
pp. 468-473
Author(s):  
Li Juan Xu ◽  
An Cui ◽  
Qiang Yang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
High Strength ◽  
Material Model ◽  
Element Model ◽  
Vehicle Body ◽  
Punch Velocity ◽  
Riveting Process ◽  
Joint Quality

With the increasing application of lightweight multi-materials in vehicle body, the SPR （self-piercing riveting）with half-hollow rivet is used to connect hybrid metals due to its simple operation and reliable connection. In this paper, appropriate size parameters of half-hollow rivet and die are selected according to sheets’ thickness after the determination of hybrid metal materials, namely FAS2205 dual phase steel, AA2036 aluminum alloy, AA7050 aluminum alloy, AA6061 aluminum alloy and 460E high strength steel. The finite element model of SPR with half-hollow rivets is constructed and the accuracy of which is proved by comparing with the experiment in the relative reference. What’s more, the Johnson-Cook constitutive model is taken as material model to simulate the plastic and hardening behaviors during riveting process. The influence on joint quality of the strength matching of rivet/bottom sheet is studied through numerical simulation and direct observation, and the relationship schematic diagram between them is gained. Meanwhile, the riveting joints at several uniform loading velocities are simulated and the quality of which are analyzed. The research results show that the appropriate matching of rivet to the bottom sheet strength is a key prerequisite for joint quality and the punch velocity plays an important role on the riveting joint quality and efficiency of assembly.

Numerical Simulation of Multi-Angle Incidence Aluminum Composite Targets with 7.62mm Piercing Armor

2014 ◽  
Vol 602-605 ◽  
pp. 562-565
Author(s):  
Yu Lei Li ◽  
Jin Jun Tang ◽  
Xiao Yu Jin ◽  
Qun Wang ◽  
Zheng Ren
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Material Model ◽  
Element Model ◽  
Target Plate ◽  
Aluminum Composite ◽  
3D Finite Element ◽  
Aluminum Target ◽  
Simulation Results ◽  
The Impact

To calculate the multi-angle penetration, this paper established a 3D finite element model of aluminum alloy plates and 7.62mm armor-piercing by using LS-DYNA software and the Johnson-Cook material model. The process of bullet penetrating 20mm thickness target with different angles of incidence was carried out. The impact of combinations on composite targets resistance projectile penetrating ability was analyzed. Simulation results show that,ballistic of composite targets can be between two aluminum target plate, clearly different combinations of composite targets for resistance to different angles of incidence between projectile penetrating relationship.

scholarly journals A Physical-Based Plane Stress Constitutive Model for High Strength AA7075 under Hot Forming Conditions

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 314
Author(s):  
Fulong Chen ◽  
Haitao Qu ◽  
Wei Wu ◽  
Jing-Hua Zheng ◽  
Shuguang Qu ◽  
...  
Keyword(s):  
Grain Size ◽  
Aluminum Alloy ◽  
Plane Stress ◽  
Metal Forming ◽  
Electron Backscatter Diffraction ◽  
High Strength ◽  
Material Model ◽  
Hot Forming ◽  
Industrial Processing ◽  
Average Grain Size

Physicallybased constitutive equations are increasingly used for finite element simulations of metal forming processes due to the robust capability of modelling of underlying microstructure evolutions. However, one of thelimitations of current models is the lack of practical validation using real microstructure data due to the difficulties in achieving statistically meaningful data at a sufficiently large microstructure scale. Particularly, dislocation density and grain size governing the hardening in sheet deformation are of vital importance and need to be precisely quantified. In this paper, a set of dislocation mechanics-based plane stress material model is constructed for hot forming aluminum alloy. This material model is applied to high strength 7075 aluminum alloy for the prediction of the flow behaviorsconditioned at 300–400 °C with various strain rates. Additionally, an electron backscatter diffraction (EBSD) technique was applied to examine the average grain size and geometrical necessary dislocation (GND) density evolutions, enabling both macro- and micro- characteristics to be successfully predicted. In addition, to simulate the experienced plane stress states in sheet metal forming, the calibrated model is further extended to a plane stress stateto accuratelypredict the forming limits under hot conditions.The comprehensively calibrated material model could be used for guidinga better selection of industrial processing parameters and designing process windows, taking into account both the formed shape as well as post formed microstructure and, hence, properties.

The Numerical Simulation of Hemispherical Parts Based on FBDF Technology

2014 ◽  
Vol 490-491 ◽  
pp. 644-648
Author(s):  
Lian Cheng Li ◽  
Ming Zhe Li ◽  
Yuan Ting Li
Keyword(s):  
Numerical Simulation ◽  
Material Parameter ◽  
Elasticity Modulus ◽  
Unit Area ◽  
Element Model ◽  
Material Surface ◽  
Damping Force ◽  
Numerical Simulation Result ◽  
Resistance To Deformation

in this paper, we mainly introduce the principle of the flexible blank drawer forming (FBDF), and establish the limited element model of the FBDF process. Then we make a numerical analysis on the hemispherical parts, and study the effect made on the result of shaping by damping force, friction coefficient as well as material parameter in per unit area. Through the analysis of the numerical simulation result, we can conclude that the greater the yield limit and elasticity modulus, the larger blank drawer force is required to form the shape; the more smooth the material surface, the less resistance to deformation will have. All this contributes to good quality of forming parts.

scholarly journals Experimental and Numerical Investigations of a Novel Laser Impact Liquid Flexible Microforming Process

Metals ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 599 ◽  
Author(s):  
Fei Liu ◽  
Huixia Liu ◽  
Chenkun Jiang ◽  
Youjuan Ma ◽  
Xiao Wang
Keyword(s):  
Numerical Simulation ◽  
Laser Energy ◽  
Pure Copper ◽  
Three Dimensional ◽  
Element Model ◽  
Force Transmission ◽  
Large Area ◽  
Laser Impact ◽  
Metallic Foils

A novel high strain rate microforming technique, laser impact liquid flexible embossing (LILFE), which uses laser induced shock waves as an energy source, and liquid as a force transmission medium, is proposed by this paper in order to emboss three-dimensional large area micro arrays on metallic foils and to overcome some of the defects of laser direct shock microembossing technology. The influences of laser energy and workpiece thickness on the deformation characteristics of the pure copper foils with the LILFE process were investigated through experiments and numerical simulation. A finite element model was built to further understand the typical stages of deformation, and the results of the numerical simulation are consistent with those achieved from the experiments. The experimental and simulation results show that the forming accuracy and depth of the embossed parts increases with the increase in laser energy and decrease in workpiece thickness. The thickness thinning rate of the embossed parts increases with the decrease of the workpiece thickness, and the severest thickness thinning occurs at the bar corner region. The experimental results also show that the LILFE process can protect the workpiece surface from being ablated and damaged, and can ensure the surface quality of the formed parts. Besides, the numerical simulation studies reveal the plastic strain distribution of embossed microfeatures under different laser energy.

Optimization Study on the Tooth Profile of Gear Shaping Roller of Honeycomb Semi-Cell Structures

2013 ◽  
Vol 423-426 ◽  
pp. 972-977
Author(s):  
Lei Qin ◽  
Yan Ting Ma ◽  
Chang Jie Luo
Keyword(s):  
Numerical Simulation ◽  
Element Model ◽  
Tooth Profile ◽  
Cell Structures ◽  
Optimization Study ◽  
Set Up ◽  
Shaping Roller ◽  
Gear Shaping ◽  
The Ideal

In order to solve the problem of low accuracy of honeycomb semi-cell structures which are rolled by traditional trapezoidal tooth profile gear shaping rollers, conjugate trapezoidal tooth profile gear shaping rollers have been put forward to improve the quality of honeycomb semi-cell structures, basing on the theoretical analysis. Using ANSYS/LS-DYNA, a finite element model of rolling aluminum foils by two kinds of tooth profile shaping rollers was set up. Then results of numerical simulation indicate that the honeycomb semi-cell structures rolled by the conjugate trapezoidal gear shaping rollers are closer to the ideal size than those rolled by the traditional trapezoidal gear shaping rollers.

Design and Optimization of FCEV Subframe by Integrated Applications of Hypermesh, UG and ADAMS Multi-Platform

2011 ◽  
Vol 328-330 ◽  
pp. 213-219
Author(s):  
Jun Liao
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Comparative Analysis ◽  
Element Model ◽  
Strength Analysis ◽  
Optimal Size ◽  
Virtual Model ◽  
Design And Optimization ◽  
New Type

The UG model and finite element model of FCEV subframe are established, and original subframe is simulated in all kinds of ADAMS environment, which result in the force of the conditions obtained. Then the virtual model is build, stiffness and strength analysis are conducted, and a new type of subframe structure is designed based on the analysis results. Magnesium alloy and aluminum alloy are used in optimization of this new structure for the optimal size. Through the comparative analysis on strength, stiffness, mode shape and quality of the new subframe and the original one, it was verified that the new subframe design is reasonable and feasible.

Sensitivity analysis and optimization of hot-stamping process of automotive components using analysis of variance and Taguchi technique

2016 ◽  
Vol 231 (4) ◽  
pp. 732-746 ◽  
Author(s):  
Abolfazl Khalkhali ◽  
Hadiseh Noraie ◽  
Morteza Sarmadi
Keyword(s):  
Numerical Simulation ◽  
Analysis Of Variance ◽  
Hot Stamping ◽  
High Strength ◽  
Vehicle Body ◽  
Design Parameters ◽  
Objective Functions ◽  
Similar Work ◽  
Stamping Process ◽  
Safety Considerations

Nowadays, the demand for achieving cars with higher strength, lower fuel consumption, and better safety considerations propels automakers to produce parts with extremely high strength-to-weight ratios. This criterion is done through the hot-stamping process considered as a novel technology employed for producing high-strength steel parts with low springback, particularly appropriate for the vehicle body. In this paper, firstly, numerical simulation of the hot-stamping process of a blank consisted of boron-alloyed steel 22MnB5 (with commercial name of Usibor 1500) is performed. Secondly, effects of different design parameters including blank holder force, die radius, gap between the punch and die, and forming time on the final temperature distributions as well as springback of the part is investigated. Consequently, optimization has been performed using Taguchi L16 orthogonal array to obtain the parameters which minimize above-mentioned parameters as two objective functions. Obtained results are verified based on performing numerical simulation and comparison to a similar work in the literature. Accuracy of the results is also assessed via the technique of plotting normal probability graphs of both objective functions. Finally, via evaluation of contribution percentage associated with analysis of variance considering each design parameter, a discussion is done by proposing the optimum design.

scholarly journals Nanosecond-Pulse Laser Assisted Cold Spraying of Al–Cu Aluminum Alloy

Coatings ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 267
Author(s):  
Chen Zhang ◽  
Dongbin Zhang ◽  
Can Luo ◽  
Weiping Peng ◽  
Xusheng Zang
Keyword(s):  
Aluminum Alloy ◽  
Pulse Laser ◽  
Bonding Strength ◽  
Substrate Surface ◽  
High Strength ◽  
Cold Spraying ◽  
Nanosecond Pulse ◽  
Forming Technology ◽  
Nanosecond Pulse Laser

In this study, nanosecond-pulse laser is used in combination with cold spraying to form a hybrid solid-state forming technology: nanosecond-pulse laser assisted cold spraying. This method successfully manufactured Al-Cu high-strength aluminum alloy coatings. The nanosecond-pulse laser reduced the porosity of the coatings. The laser-induced micro-texture on the substrate surface had the ability of improving the bonding strength of the coating-substrate interface. The bonding strength was closely related to the depth of the micro-texture. The deeper micro-texture caused an unfused interface on the bottom of the texture, which produced voids and reduced the bonding strength. The nanosecond-pulse lasers can also increase the hardness of the coatings. The assistance of the nanosecond-pulse laser has proved to be an effective method to improve the quality of cold sprayed metal coatings.

Behavior and Quality Evaluation of Electroplastic Self-Piercing Riveting of Aluminum Alloy and Advanced High Strength Steel

2013 ◽  
Vol 135 (1) ◽  
Author(s):  
Ming Lou ◽  
YongBing Li ◽  
YaTing Li ◽  
GuanLong Chen
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
High Strength Steel ◽  
High Strength ◽  
Tensile Shear Strength ◽  
Advanced High Strength Steel ◽  
Tensile Shear ◽  
Cold Forming ◽  
Riveting Process ◽  
Cross Tension

The hybrid use of dissimilar lightweight materials, such as aluminum alloy and advanced high strength steel (AHSS), has become a critical approach to reduce the weight of ground transportation vehicles. Self-piercing riveting (SPR) as a preferred cold-forming fastening method is facing problems like weak interlocking and insufficient penetration, due to the reduced formability of AHSS. In this paper, a new process named electroplastic self-piercing riveting (EP-SPR) was proposed to reduce the deformation resistance of AHSS DP780, by applying a direct current (dc) to it during the riveting process. The influence of dc on force and displacement characteristics throughout the riveting process, joint physical attributes and quasi-static performances for two sheet combinations, e.g., AA6061-T6 to DP780 (combination 1) and DP780 to AA6061-T6 (combination 2), were studied and compared with the traditional SPR joints. The results showed that compared with the traditional SPR joints, the EP-SPR ones increased by 12.5% and 23.3% in tensile-shear strength and cross-tension strengths for combination 1, respectively. For combination 2, even though the EP-SPR joints decreased by 5.8% in tensile-shear strength, it could reduce the penetration risk of bottom AA6061-T6, and present a better energy absorption capability for the increased undercut amount. In addition, the corresponding cross-tension strength of EP-SPR joints still increases by 6.1%.

Research on Stamping of Aluminum Alloy Hemispherical Components Based on Numerical Simulation and Experiments

2010 ◽  
Vol 97-101 ◽  
pp. 236-239
Author(s):  
Cheng Jun Han ◽  
Xin Bo Lin ◽  
Yan Bo Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Product Quality ◽  
Experimental Research ◽  
Simulation Software ◽  
Blank Holder Force ◽  
Forming Process ◽  
Blank Holder ◽  
Wrought Aluminum

Experimental research on stamping of wrought aluminum alloy has been an important issue at home and abroad. In this paper, taking stamping of aluminum alloy hemispherical components for example, the effects of blank holder force (BHF) on stamping forming process of aluminum alloy are explored by methods of experiments and numerical simulation. Through experiments, the forming laws of hemispherical components are found out. The research shows that the BHF has significant effects on the quality of stamping components and reasonable BHF can greatly improve the formability of hemispherical components. Additionally, by applying simulation software in stamping, the development circle of product and its moulds can be shortened, and product quality and its competitiveness in the market can be improved.

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