The Study on Numerical Simulation of Tailor Welded Blanks on Square Cup Stamping

2011 ◽  
Vol 189-193 ◽  
pp. 3932-3935
Author(s):  
Xiao Gang Qiu
Keyword(s):  
Numerical Simulation ◽  
Plastic Deformation ◽  
Strain Distribution ◽  
Weld Seam ◽  
Element Model ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Tailor Welded Blank ◽  
Different Thickness ◽  
The Finite Element Model

The stamping process of the tailor welded blank(TWB) was simulated by the software of DYNAFORM. The finite element model of a boxy part was founded, and the forming of different thickness and properties of the material was studied. Meanwhile, the influence of weld seam on forming result was analyzed. The results show that the weld seam model which founded by real properties can describe the plastic deformation and strain distribution more exactly in the forming process.

Numerical Simulation and Test Research of Continuous Flexible Forming Process for the Spherical Parts

2011 ◽  
Vol 291-294 ◽  
pp. 269-272
Author(s):  
Ying Wu Lan ◽  
Zhong Yi Cai ◽  
Ming Zhe Li
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Longitudinal Deformation ◽  
Forming Process ◽  
Flexible Forming ◽  
Sensing System ◽  
Flexible Forming Process ◽  
The Finite Element Model

The deformation of sheet metal in the continuous flexible forming (CFF) process is complex and the formed result is affected by many factors. In this paper, the finite element model of CFF was founded and the forming processes of spherical parts were simulated with the software ABAQUS. The interaction between transversal deformation and longitudinal deformation in the CFF process is analyzed. Based on results of numerical simulation and forming tests, the process parameters of CFF is revised, and formed surface is measured by three dimensional sensing system, the measured results indicate the precision of formed parts are satisfactory.

Comparison of Analytical Model to Experimental and Numerical Simulations Results for Tailor Welded Blank Forming

2006 ◽  
Vol 129 (1) ◽  
pp. 211-215 ◽  
Author(s):  
Matt Bravar ◽  
Neil Krishnan ◽  
Brad Kinsey
Keyword(s):  
Numerical Simulation ◽  
Plane Strain ◽  
Analytical Model ◽  
Weld Line ◽  
Forming Process ◽  
Tailor Welded Blanks ◽  
Industrial Utilization ◽  
Tailor Welded Blank ◽  
Weld Line Movement ◽  
Plane Strain Assumption

Tailor welded blanks (TWBs) offer several notable benefits including decreased part weight, reduced manufacturing costs, and improved dimensional consistency. However the reduced formability and other characteristics of the forming process associated with TWBs has hindered the industrial utilization of this blank type for all possible applications. One concern with TWB forming is that weld line movement occurs, which alters the final location of the various materials in the TWB combination. In this technical brief, an analytical model to predict the initial weld line placement necessary to satisfy the desired, final weld line location and strain at the weld line is used. Results from this model are compared to an experimental, symmetric steel TWB case and a 3D numerical simulation, nonsymmetric aluminum TWB case. This analytical model is an extension of one previously presented, but eliminates a plane strain assumption that is unrealistic for most sheet metal forming applications. Good agreement between the analytical model, experimental, and numerical simulation results with respect to initial weld line location was obtained for both cases. Results for the model with a plane strain assumption are also provided, demonstrating the importance of eliminating this assumption.

scholarly journals Formability study and metallurgical properties analysis of FSWed AA 6061 blank by the SPIF process

2021 ◽  
Vol 3 (3) ◽  
Author(s):  
Payam Tayebi ◽  
Ali Fazli ◽  
Parviz Asadi ◽  
Mahdi Soltanpour
Keyword(s):  
Base Metal ◽  
Strain Distribution ◽  
Thickness Distribution ◽  
Experimental Studies ◽  
Welding Process ◽  
Forming Limit ◽  
Forming Process ◽  
Friction Stir ◽  
Numerical Process ◽  
Tailor Welded Blank

AbstractIn this study, in order to obtain the maximum possible formability in tailor-welded blank AA6061 sheets connected by the friction stir welding (FSW) procedure, the incremental sheet forming process has been utilized. The results are presented both numerically and experimentally. To obtain the forming limit angle, the base and FSWed sheets were formed in different angles with conical geometry, and ultimately, the forming limit angle for the base metal and FSWed sheet is estimated to be 60° and 57.5°, respectively. To explore the effects of welding and forming procedures on AA6061 sheets, experimental studies such as mechanical properties, microstructure and fracture analysis are carried out on the samples. Also, the thickness distribution of the samples is studied to investigate the effect of the welding process on the thickness distribution. Then, the numerical process was simulated by the ABAQUS commercial software to study the causes of the FSWed samples failure through analyzing the thickness distribution parameter, and major and minor strains and the strain distribution. Causes of failure in FSWed samples include increased minor strain, strain distribution and thickness distribution in welded areas, especially in the proximity of the base metal area.

Numerical Simulation Analysis for Enclosure Piles Cracking of a Deep Pit Foundation

2011 ◽  
Vol 109 ◽  
pp. 276-280
Author(s):  
Ji Chao Zhang ◽  
Yong Kang Yang ◽  
Yong Xu
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Element Model ◽  
Wind Load ◽  
Load Direction ◽  
Foundation Pit ◽  
Deep Pit ◽  
Disadvantageous Factors ◽  
Construction Condition ◽  
The Finite Element Model

Based on the appearance of crack of enclosure piles on a foundation pit, Midas GTS is adopted to establish the finite element model. Through the numerical simulation, the influence of the direction of wind load, wind scale and prestress of anchor are analyzed, the worst wind load direction, unfavorable construction condition, maximum moment of enclosure piles are ensured, crack width in different disadvantageous factors are calculated, which provides a guide for continuous construction.

Study on Formability Characteristics of the Weld Seam of Aluminum Steel Tailored Hybrid Blanks

2013 ◽  
Vol 549 ◽  
pp. 302-310 ◽  
Author(s):  
Ozan Singar ◽  
Marion Merklein
Keyword(s):  
Automobile Industry ◽  
Weld Seam ◽  
Weld Line ◽  
Tensile Tests ◽  
Forming Process ◽  
Manufacturing Costs ◽  
Tailor Welded Blanks ◽  
Welding Technology ◽  
Tailored Blanks ◽  
Cmt Welding

Tailor Welded Blanks (TWB) are characterized by the fact that sheets with different material qualities and/or thicknesses are welded together before the forming process. The application of TWBs in the automobile industry brings several advantages, such as the reduction of car body weight and manufacturing costs, as well as the integration of several drawing parts into one part. Despite several established tailor welded blanks types, a new version has emerged: The Tailored Hybrid Blanks (THB). The current investigation focuses on tailored hybrid blanks joined by the CMT-welding technology. The main aim of this study is to specify the mechanical properties as well as the formability of Aluminum Steel Tailored Blanks. Steel (HX340LAD, 0.8 mm) sheets covered by different zinc coat thicknesses were combined with an aluminum alloy (AA6014-T4, 1.2 mm). In order to determine the material properties and to analyze the Heat Affected Zone (HAZ), microhardness measurements were taken transversal and longitudinal to the weld line. Results indicate a change of hardness and a very small HAZ. Tensile tests (perpendicular to weld line) and Nakajima tests with online deformation analyses show that the main formation takes place on the aluminum side.

scholarly journals The Effect of Swinging Ball Heads with Different Arrangements in Multi-Point Stretch-Forming Process

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 337 ◽  
Author(s):  
Jian Xing ◽  
Yan-yan Cheng ◽  
Zhuo Yi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Sheet Metal ◽  
Strain Distribution ◽  
Finite Element Models ◽  
Stretch Forming ◽  
Forming Process ◽  
Forming Quality ◽  
Staggered Arrangement ◽  
Simulation Results

To improve the effect of multi-point stretch forming of sheet metal, it is proposed in this paper to replace a fixed ball head with a swinging ball head. According to the multi-point dies with different arrangements, this research establishes finite element models of the following stretch forming, i.e., fixed ball heads with conventional arrangement, swinging ball heads with conventional arrangement, swinging ball heads with declining staggered arrangement, and swinging ball heads with parallel staggered arrangement, and then numerical simulation is performed. The simulation results show that by replacing a fixed ball head with a swinging ball head, the surface indentation of the part formed was effectively suppressed, the stress and tension strain distribution of the part formed was improved, and the forming quality was improved; the thickness of the elastic pad was reduced, the springback was reduced and the forming accuracy was improved; and when the ball head was applied to a multi-point die with staggered arrangement, a better forming result was achieved, where the best forming result was achieved in combining the swinging ball heads with the multi-point die with a parallel staggered arrangement. Forming experiments were carried out, and the experimental results were consistent with the trend of numerical simulation results, which verified the correctness of the numerical simulation.

Research on the Straightening Deformation Process of the Residual Stress of the Numerical Simulation for Different Kinds of Heavy Rail

2012 ◽  
Vol 430-432 ◽  
pp. 492-496
Author(s):  
Yu Yan Liu ◽  
Hao Li ◽  
Lin Chen
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Finite Element ◽  
Deformation Process ◽  
Element Model ◽  
Regional Deformation ◽  
Distribution Rule ◽  
Deformation Area ◽  
The Finite Element Model ◽  
Heavy Rail

Through out the establishment of heavy rail entity model and the finite element model of straightening for different kinds of heavy rail after the residual stress in straightening investigated . Analysed U75V、U76CrRE、U71Mn and U75VM the four different kinds in 8+1 level straightening of the seven regional deformation area rail head, rail waist, rail base vertical stress distribution rule.

Numerical Simulation and Parameter Study of Radial Forging of Conical Tube

2020 ◽  
Vol 861 ◽  
pp. 514-518
Author(s):  
Xin Hai Zhao ◽  
Xin Bo Ren ◽  
Xing Chen Sun ◽  
Chao Zheng ◽  
Li Bin Song ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Reference Value ◽  
Element Model ◽  
Parameter Study ◽  
Radial Forging ◽  
Influence Of Process Parameters ◽  
Forming Quality ◽  
Forging Process ◽  
Radial Forging Process ◽  
The Finite Element Model

The cone tube is an important part of the circuit connector, which has high requirements for its forming quality. In this paper, the cone tube is taken as the object, the finite element model is established, the radial forging process of the cone tube is simulated, the influence of process parameters such as axial feed and friction on the thickness of the cone tube is studied, and the influence law is analyzed, which has certain reference value for the analysis of the forming law of the radial forging.

FE Simulation of Vacuum Hot Bulge Forming Process of BT20 Ti-Alloy Cylindrical Workpiece

2008 ◽  
Vol 392-394 ◽  
pp. 366-369
Author(s):  
Ming Wei Wang ◽  
Li Wen Zhang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Heating Temperature ◽  
Radiation Heat Transfer ◽  
Element Model ◽  
Ti Alloy ◽  
Forming Process ◽  
Relaxation Theory ◽  
Finite Element Software ◽  
Cylindrical Workpiece

The vacuum hot bulge forming has been used in aerospace industry to manufacture cylindrical workpiece with improved mechanical properties and reduced fabrication cost. Vacuum hot bulge forming is based on the material soften and the stress relaxation theory. Different from other metal forming techniques, deformation of the workpiece takes place well below yield point and the amount of plastic deformation is directly relaxed to heating temperature and holding time. In this paper, a two-dimension thermo-mechanical coupled finite element model was developed. In this model, nonlinear radiation heat transfer and thermal physical properties of material depending on temperature were considered. This paper carried out numerical simulation of vacuum hot bulge forming of BT20 Ti-alloy cylindrical workpiece by using finite element software MSC.Marc. The temperature field, deformation field and stress field of hot bulge forming of BT20 Ti-alloy cylindrical workpiece were calculated. Numerical simulation results were accorded with experimental ones, which provided for the practice production as theory bases.

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