Research of Process Parameters of Screwy Thin-Walled Part with Coaxial Inside-Beam Powder Feeding Accumulation

2014 ◽  
Vol 528 ◽  
pp. 185-190
Author(s):  
Yu Liu ◽  
Ge Yan Fu ◽  
Shi Hong Shi ◽  
Ming Jun Wu
Keyword(s):  
Laser Cladding ◽  
Process Parameters ◽  
Wall Thickness ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Continuous Laser ◽  
Forming Process ◽  
Scanning Path ◽  
Thin Walled ◽  
Powder Feeding

Based on the technology of laser cladding manufacturing process with coaxial inside-beam powder feeding, screwy thin-walled part is accumulated on the substrate of 45# steel by controlling the angle of inclination, scanning paths, Z axis incremental and power. Through the inclined wall accumulation model and a large number of tests, limiting angle of the cladding accumulation is obtained. According to the forming process of screwy thin-walled part, two scanning paths are designed, which include continuous laser scanning between each layer and intermittent laser scanning between each layer, the better scanning path is gained by analyzing each path. A good forming part is obtained by controlling Z axis incremental and power simultaneously. The forming part is higher with smooth appearance and lower roughness, and wall thickness is uniformed.

Effect of Scanning Path on Microstructure and Microhardness of Laser Cladding Ti-6Al-4V Alloy

2010 ◽  
Vol 154-155 ◽  
pp. 147-150
Author(s):  
Dong Jiang Wu ◽  
Qian Li ◽  
Xiao Kang Liang ◽  
Yun Xiao Chen
Keyword(s):  
Epitaxial Growth ◽  
Laser Cladding ◽  
Laser Scanning ◽  
Scanning Direction ◽  
Scanning Path ◽  
Cladding Layers ◽  
Powder Feeding

Ti-6Al-4V laser cladding layers were performed on the Ti substrate respectively based on four different laser scanning ways by laser cladding with coaxial powder feeding. The results showed that the morphology of cladding layers in heat overlapping was much smoother than cold overlapping. The possibility of appearance of concave-convex would be increased in the laser cladding performed with reverse scanning direction. However with same direction scanning the possibility of distortion of the substrate would increase. The microstructure of cladding layers in four scanning ways all exhibit epitaxial growth huge columnar β grains in which fine acicular α and Widmanstaten α lath are distributed. The columnar β grains and fine acicular α formed during cold overlapping were denser than during heat overlapping. Also the microhardness of laser cladding zone was improved compared to the substrate no matter in which scanning way while the microhardness in cold overlapping was higher than that in heat overlapping in the same position of cladding zone.

Numerical Simulation on Temperature Field in Multi-Layers Inside-Beam Powder Feeding when Laser Cladding

2012 ◽  
Vol 499 ◽  
pp. 114-119 ◽  
Author(s):  
Ming Di Wang ◽  
Shi Hong Shi ◽  
X.B. Liu ◽  
Cheng Fa Song ◽  
Li Ning Sun
Keyword(s):  
Numerical Simulation ◽  
Heat Source ◽  
Laser Beam ◽  
Cooling Rate ◽  
Light Source ◽  
Laser Cladding ◽  
Laser Scanning ◽  
Initial Conditions ◽  
Cladding Layer ◽  
Powder Feeding

Numerical simulation of laser cladding is the main research topics for many universities and academes, but all researchers used the Gaussian laser light source. Due to using inside-beam powder feeding for laser cladding, the laser is dispersed by the cone-shaped mirror, and then be focused by the annular mirror, the laser can be assumed as the light source of uniform intensity.In this paper,the temperature of powder during landing selected as the initial conditions, and adopting the life-and-death unit method, the moving point heat source and the uniform heat source are realized. In the thickness direction, using the small melt layer stacking method, a finite element model has been established, and layer unit is acted layer by layer, then a virtual reality laser cladding manu-facturing process is simulated. Calculated results show that the surface temperature of the cladding layer depends on the laser scanning speed, powder feed rate, defocus distance. As cladding layers increases, due to the heat conduction into the base too late, bath temperature will gradually increase. The highest temperature is not at the laser beam, but at the later point of the laser beam. In the clad-ding process, the temperature cooling rate of the cladding layer in high temperature section is great, and in the low-temperature, cooling rate is relatively small. These conclusions are also similar with the normal laser cladding. Finally, some experiments validate the simulation results. The trends of simulating temperature are fit to the actual temperature, and the temperature gradient can also ex-plain the actual shape of cross-section.

Methods, Models, and Assumptions Used in Finite Element Simulation of a Pilger Metal Forming Process

2003 ◽  
Author(s):  
John Martin
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Defect Formation ◽  
Process Parameter ◽  
Stress And Strain ◽  
Finite Element Software ◽  
Sensitivity Studies ◽  
Modelling Techniques ◽  
Thin Walled

The pilger process is a cold-worked mechanical process that combines the elements of extrusion, rolling, and upsetting for the formation of thin-walled tubes. This complex manufacturing process relies on the results of trial and error testing programs, experimental parameter sensitivity studies, and prototypical applications to advance the technology. This finite element modelling effort describes the methods, models, and assumptions used to assess the process parameters used to manufacture thin-walled tubing. The modelling technique breaks down the manufacturing process into smaller computer generated models representing fundamental process functions. Each of these models is linked with the overall process simulation. Simplified assumptions are identified and supporting justifications provided. This work represents proof of principle modelling techniques, using large deformation, large strain, finite element software. These modelling techniques can be extended to more extensive parameter studies evaluating the effects of pilger process parameter changes on final tube stress and strain states and their relationship to defect formation/propagation. Sensitivity studies on input variables and the process parameters associated with one pass of the pilger process are also included. The modelling techniques have been extended to parameter studies evaluating the effects of pilger process parameter changes on tube stress and strain states and their relationship to defect formation. Eventually a complex qualified 3-D model will provide more accurate results for process evaluation purposes. However, the trends and results reported are judged adequate for examining process trends and parameter variability.

Laser Cladding Forming of Cantilevered Thin-Walled Part Based on Hollow-Laser Beam Inside Powder Feeding Technology2

2015 ◽  
Vol 42 (10) ◽  
pp. 1003003
Author(s):  
石拓 Shi Tuo ◽  
王伊卿 Wang Yiqing ◽  
卢秉恒 Lu Bingheng ◽  
石世宏 Shi Shihong ◽  
陆斌 Lu Bing ◽  
...  
Keyword(s):  
Laser Beam ◽  
Laser Cladding ◽  
Thin Walled ◽  
Hollow Laser Beam ◽  
Powder Feeding

Research on Laser Cladding Forming Process of Circumferentially Inclined Thin-Walled Cylinders

2018 ◽  
Vol 45 (8) ◽  
pp. 0802004
Author(s):  
孙佳钰 Sun Jiayu ◽  
于天彪 Yu Tianbiao ◽  
赵雨 Zhao Yu ◽  
杨林 Yang Lin ◽  
关闯 Guan Chuang
Keyword(s):  
Laser Cladding ◽  
Forming Process ◽  
Thin Walled

scholarly journals Investigation on precision and performance for hot gas forming of thin-walled components of Ti2AlNb-based alloy

2018 ◽  
Vol 190 ◽  
pp. 07001
Author(s):  
Xueyan Jiao ◽  
Zhiqiang Liu ◽  
Yong Wu ◽  
Gang Liu
Keyword(s):  
Process Parameters ◽  
Microstructure Evolution ◽  
Element Model ◽  
Parameters Optimization ◽  
Forming Process ◽  
Performance Control ◽  
Hot Gas ◽  
Thin Walled ◽  
And Performance ◽  
Hot Gas Forming

Ti2AlNb-based alloys have received considerable attention as potential materials to replace the nickel alloy at 600-750 °C, depending on their advantages of high specific strength, good corrosion and oxidation resistance. To realize the precision and performance control for Ti2AlNb-based alloy thin-walled components, the microstructure evolution was analyzed for setting up the unified viscoplastic constitutive equations based on the physical variables and simulating the forming process coupled between the deformation and the microstructure evolution. Through the finite element model with coupling of microstructure and mechanical parameters, the microstructure evolution and shape fabricating can be predicted at the same time, to provide the basis for the process parameters optimization and performance control. With the reasonable process parameters for hot gas forming of Ti2AlNb thin-walled components, the forming precision and performance can be controlled effectively.

MINIMUM WALL THICKNESS OF HOLLOW THREADED PARTS IN THREE-DIE COLD THREAD ROLLING

2008 ◽  
Vol 22 (31n32) ◽  
pp. 6112-6117 ◽  
Author(s):  
HUIPING QI ◽  
YONGTANG LI ◽  
JIANHUA FU ◽  
ZHIQI LIU
Keyword(s):  
Wall Thickness ◽  
High Efficiency ◽  
Low Cost ◽  
Work Piece ◽  
Forming Process ◽  
Minimum Thickness ◽  
Thread Rolling ◽  
Thin Walled ◽  
Rolling Technology ◽  
Good Agreement

The cold thread rolling technology was developed rapidly in recent years due to its high efficiency, low cost and perfect mechanical properties of its production. However, researches on the precise thread rolling of the hollow parts were very few. Traditionally, the minimum thickness of the thin-walled threaded parts by thread rolling was mainly determined by the empirical (trial and error) methods. In this study, the forming process of thin-walled thread parts rolled with three thread rolling dies was analyzed. The stress state of the hollow work piece was obtained by solving the statically indeterminate problems. Then, the equations for the minimum wall thickness were derived. Experiments are also performed. The experimental results are generally in good agreement with those by the current theoretical analysis. It could be concluded that the analysis presented in this study can provide a good guidance for the thread rolling of hollow parts.

Effect of Defocus Distance on Layer Quality in Insider-Laser Coaxial Powder Feeding Laser Cladding

2011 ◽  
Vol 287-290 ◽  
pp. 2419-2422
Author(s):  
Hou Shun Sun ◽  
Shi Hong Shi ◽  
Ge Yan Fu ◽  
Jia Zhang ◽  
Chen Wang ◽  
...  
Keyword(s):  
Surface Quality ◽  
Laser Cladding ◽  
Process Parameters ◽  
High Ratio ◽  
Metal Part ◽  
Laser Cladding Process ◽  
Surface Flatness ◽  
Powder Feeding

Insider-laser coaxial powder feeding laser cladding is one kind of technique, which can be used in metal part directly manufacturing field. Compared with outsider-laser coaxial powder feeding laser cladding techniques, it has significant advantages [1]. In order to research the effect of defocus distance on the layer quality in insider-laser coaxial powder feeding laser cladding, it has taken some expriments in this paper to study the layer quality by constantly changing the defocus distance, with other laser cladding process parameters invariable. In addition, this paper measues, analysis the cladding layer’s width, height, the surface quality (including surface flatness, flat-wide ratio and flat-high ratio [2]), hardness and microstructure, then summarizes the effect of the defocus distance on the layer quality in this paper.

Temperature Field Numerical Simulation of Screwy Thin-Walled Part Cladded by Hollow Laser Beam

2013 ◽  
Vol 779-780 ◽  
pp. 410-413
Author(s):  
Hao Lin ◽  
Shi Hong Shi
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Laser Beam ◽  
Laser Cladding ◽  
Molten Pool ◽  
Laser Power ◽  
Forming Process ◽  
Single Laser ◽  
Thin Walled ◽  
Hollow Laser Beam

A numerical simulation model of laser cladding based on internal powder feeding through a hollow laser beam is set up by the Ansys Parametric Design Language (APDL). Through analyzing this model, the saddle-shaped distribution of energy absorbed in scanning direction is found and the molten pool temperature field of single laser cladding is observed like a comet[. Base on the single laser cladding experiments, the initial parameters and test plans of laser cladding and the screwy thin-walled part forming are confirmed. The finite element model of laser cladding forming screwy thin-walled part is established. The evolution of temperature field and thermal cycle of the nodes are studied during the screwy thin-walled part forming process. In the emulation laser power is controlled real time according to the analyses above, and the changing value of laser power is obtained to keep the molten pool temperature steady. The screwy thin-walled part is formed successfully based on these data.

Process Parameter Optimization for Better Hydro-Forming Performance of a Trailing Arm Tube

2013 ◽  
Vol 465-466 ◽  
pp. 704-708
Author(s):  
Shen Yung Lin ◽  
Hong Yi Liao
Keyword(s):  
Process Parameters ◽  
Wall Thickness ◽  
Tube Wall ◽  
Thickness Distribution ◽  
Equivalent Stress ◽  
Process Parameter ◽  
Hydraulic Pressure ◽  
Forming Process ◽  
Tube Wall Thickness ◽  
Forming Characteristics

This work presents the tube forming characteristics of a trailing arm which the whole forming processes are arranged through pre-bending twice and hydro-forming once. This work utilizes the finite element method to simulate the hydro-forming process of the trailing arm by changing the process parameters, such as velocity of left and right punches and internal hydraulic pressure, etc. The effects of process parameters on the distribution states of the tube wall-thickness, distribution of equivalent stresses and strains, and formability of the forming arm are thus investigated. Taguchi method, orthogonal array and factor response are then applied together to determine the optimal process parameter combinations corresponding to two single-quality objects, minimum tube wall-thickness and maximum equivalent stress, with nominal-the-best and smaller-the-better, respectively. It shows that the velocity of the right punch for the billet material axial feeding supplement should be larger than that of the left punch preventing the uneven bursting of the tube-wall on right-end. The analysis of variance also shows that left punch velocity is a major contribution parameter for tube wall-thickness while that primarily affects the equivalent stress is the internal pressure.

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