Numerical Study on Forming Process by Continuous Resistance Heating

2010 ◽  
Vol 154-155 ◽  
pp. 867-872
Author(s):  
Zheng Xing Men ◽  
Jie Zhou ◽  
Meng Han Wang ◽  
Chang Wei Shao
Keyword(s):  
Temperature Distribution ◽  
Contact Resistance ◽  
Numerical Study ◽  
Mechanical Analysis ◽  
Transient Temperature ◽  
Resistance Heating ◽  
Forming Force ◽  
Forming Process ◽  
Billet Temperature ◽  
Die Geometry

In the present study, an axis-symmetric electro-thermo-mechanical model has been developed to analyze a deformation process by continuous resistance heating. To obtain the transient temperature field prior to forming, a novel temperature-dependent model of the contact resistance was developed in the thermal-electrical analysis. The influences of the contact resistance, the current intensity and the die geometry on the temperature distribution were investigated. In the subsequent electro-thermo-mechanical analysis of the forming process by continuous resistance heating, the variations of the billet temperature distribution, forming force were obtained. The simulation results correspond well with experimental measured values. Furthermore, the influence of a current increasing during forming on the billet temperature and forming force was predicted in order to optimize the forming technology by continuous resistance heating.

scholarly journals Application of Direct Resistance Heating in Hot Forging and Analysis of Processing Parameters based on Thermo-electro-mechanical Coupling FEM

2018 ◽  
Vol 37 (6) ◽  
pp. 531-538
Author(s):  
Men Zhengxing ◽  
Wang Menghan ◽  
Ma Yaxin ◽  
Yue Taiwen ◽  
Liu Ruilin
Keyword(s):  
Contact Resistance ◽  
Heating Temperature ◽  
Hot Forging ◽  
Processing Parameters ◽  
Experimental Results ◽  
Transient Temperature ◽  
Resistance Heating ◽  
Forming Process ◽  
Mechanical Coupling ◽  
Forming Temperature

AbstractA series of experiments were designed in order to directly heat the billet of 42CrMo4 to the forming temperature in the dies prior to forming and continue to heat the billet during the forming process. Processing parameters during heating and forming were investigated by experimental method and thermo-electro-mechanical coupling FEM. The experimental results show that prior to forming the billet could be rapidly heated to forming temperature under relatively low initial contact pressure, and the heating temperature was proportional to the square of the current intensity. When the heating current remained constant, the heating temperature could not increase with heating time. During the forming process, the billet cooling rate slowed down and the forming time was extended due to the continuous resistance heating during forming. Finally, an incrementally coupled thermo-electro-mechanical model has been developed to analyze the hot-forging process by direct resistance heating. To obtain the transient temperature field prior to forming, a simple model of contact resistance was used in the thermal-electrical simulation, in which the electrical conductance of the contact resistance was proportional to the heating temperature. Contrasted the experimental results and the simulation results, it was found that they coincided well.

An Experimental and Numerical Study on Forming Force, Fracture Behavior, and Strain States in Two Point Incremental Forming Process

2016 ◽  
Vol 725 ◽  
pp. 586-591
Author(s):  
Chen Hao Wang ◽  
William J.T. Daniel ◽  
Hai Bo Lu ◽  
Sheng Liu ◽  
Paul Anthony Meehan
Keyword(s):  
Plastic Strain ◽  
Fracture Behavior ◽  
Numerical Study ◽  
Equivalent Plastic Strain ◽  
Fem Simulation ◽  
Forming Force ◽  
Forming Process ◽  
Approaches To Study ◽  
Tool Diameter ◽  
Numerical Approaches

Two-point incremental sheet forming process (TPIF) is an emerging and promising manufacturing process for the production of complex geometries or customized functional sheet components. In this study, the single-pass TPIF process is investigated using experimental and numerical approaches to study the forming force evolution, fracture behavior and strain states with a varied wall angle hemisphere shape. It can be concluded that both the peak force and fracture depth increases with tool diameter and incremental depth in TPIF process. It seems the deformation mechanism or the failure mechanism is strongly dependent on particular forming conditions based on a failure parts morphology observation. FEM simulation results indicated that the major plastic strain is positive while the minor plastic strain is negative in the TPIF process on a hemiphere shape. it can be concluded that the strain increment and total equivalent plastic strain is affected by both tool diameter and incremental depth.

An experimental and numerical study of the expansion forming of a thick-walled microgroove tube

2008 ◽  
Vol 223 (3) ◽  
pp. 689-697 ◽  
Author(s):  
D Tang ◽  
Y Peng ◽  
D Li
Keyword(s):  
Mechanical Performance ◽  
Numerical Study ◽  
Surface Profile ◽  
Processing Parameters ◽  
Forming Process ◽  
Axial Section ◽  
Die Geometry ◽  
Contact Points ◽  
Industrial Sectors ◽  
Full Contact

CO2 refrigerant-based air conditioning and refrigeration (ACR) is an increasing concern in many industrial sectors for its zero ozone depletion potential. One of the major requirements in its application is the forming technology of thick-walled tube according to the extremely high pressure working conditions of the ACR system. This article presents a study on the expansion process joining the thick-walled microgroove copper tube to aluminium fins. Experiments of the forming process have been carried out. Finite-element models are developed to investigate the deformation of overall and local structures. Evaluation of the joining quality along the longitude axis of the tube is first attempted. The agreement of the results on the contact surface profile confirms that the joint is far away from full contact in the axial section. Formation mechanism of the unexpected contact status lies in displacement of the contact points along the section of the fin collar, which is mainly related to the expanding ratio. To improve the forming quality, discussion on processing parameters and die geometry is conducted. Results show that the expanding ratio is the major factor influencing the thermal—mechanical performance of the joint and 2–6 per cent can be the comprehensively beneficial range for a thick-walled ACR tube; average contact pressure can reach 1.76 Mpa under proper set. The results are helpful for improving the energy efficiency ratio performance of the natural refrigerant-based system.

Schwingungsüberlagertes Axialformen/Superimposed Oscillated Axial Forming

2020 ◽  
Vol 110 (11-12) ◽  
pp. 838-843
Author(s):  
Philipp Müller ◽  
Bernd-Arno Behrens ◽  
Sven Hübner ◽  
Hendrik Vogt ◽  
Daniel Rosenbusch ◽  
...  
Keyword(s):  
Surface Quality ◽  
Economic Importance ◽  
Combined Effect ◽  
Wird Eine ◽  
Forming Force ◽  
Forming Process ◽  
Forming Technology ◽  
Great Economic Importance ◽  
Gear Geometry

Techniken zur Steigerung der Formgebungsgrenzen in der Umformtechnik sind von hoher wirtschaftlicher Bedeutung. In dieser Arbeit wird eine Schwingungsüberlagerung im Krafthauptfluss eines Axialformprozesses zur Ausprägung einer Verzahnungsgeometrie untersucht. Die Auswirkungen der Schwingung auf die erzielbare Ausfüllung der Zahnkavitäten werden analysiert sowie die Parameter Schmierung und Oberflächengüte der Halbzeuge in ihrer kombinierten Wirkung untersucht. Es konnte eine Reduzierung der mittleren Umformkraft sowie eine Erhöhung der Formfüllung festgestellt werden. Techniques for extending the production limits in forming technology are of great economic importance. In this research, a superimposed oscillation in the main force flow of an axial forming process to form an axial gear geometry is investigated. The effects of the superimposed oscillation on the achievable form-filling of the tooth cavities are analyzed and the parameters lubrication and surface quality of the semi-finished products are investigated in their combined effect. A reduction of the averaged forming force as well as an increase of the form-filling could be achieved.

Boundary Condition Design to Heat a Moving Object at Uniform Transient Temperature Using Inverse Formulation

2004 ◽  
Vol 126 (3) ◽  
pp. 619-626 ◽  
Author(s):  
Hakan Ertu¨rk ◽  
Ofodike A. Ezekoye ◽  
John R. Howell
Keyword(s):  
Boundary Condition ◽  
Temperature Distribution ◽  
Design Problem ◽  
Manufacturing Industry ◽  
Three Dimensional ◽  
Chemical Deposition ◽  
Iterative Solution ◽  
Conveyor Belt ◽  
Temperature History ◽  
Transient Temperature

The boundary condition design of a three-dimensional furnace that heats an object moving along a conveyor belt of an assembly line is considered. A furnace of this type can be used by the manufacturing industry for applications such as industrial baking, curing of paint, annealing or manufacturing through chemical deposition. The object that is to be heated moves along the furnace as it is heated following a specified temperature history. The spatial temperature distribution on the object is kept isothermal through the whole process. The temperature distribution of the heaters of the furnace should be changed as the object moves so that the specified temperature history can be satisfied. The design problem is transient where a series of inverse problems are solved. The process furnace considered is in the shape of a rectangular tunnel where the heaters are located on the top and the design object moves along the bottom. The inverse design approach is used for the solution, which is advantageous over a traditional trial-and-error solution where an iterative solution is required for every position as the object moves. The inverse formulation of the design problem is ill-posed and involves a set of Fredholm equations of the first kind. The use of advanced solvers that are able to regularize the resulting system is essential. These include the conjugate gradient method, the truncated singular value decomposition or Tikhonov regularization, rather than an ordinary solver, like Gauss-Seidel or Gauss elimination.

scholarly journals Numerical study on temperature distribution of tunnel structure in fires

2021 ◽  
Vol 25 ◽  
pp. 100874
Author(s):  
Xin Xu ◽  
Guoqing Zhu ◽  
Xiaojin Zhang ◽  
Guoqiang Chai ◽  
Tianwei Chu
Keyword(s):  
Temperature Distribution ◽  
Numerical Study ◽  
Tunnel Structure

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.

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