Efficacy Rack Angle on the Orthogonal Machining of AA5083 in the Cutting Force

2011 ◽  
Vol 189-193 ◽  
pp. 4391-4395
Author(s):  
Behnam Davoodi ◽  
Mohammad Bagher Momeni ◽  
Faramarz Ashenai Ghasemi
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Experimental Measurement ◽  
Rake Angle ◽  
Forming Process ◽  
Aluminum Alloy 5083 ◽  
Orthogonal Machining ◽  
Simulation Results

In recent years technology manufacturing is expanding daily. Modern machining industry has found a special place. The separation chip forming process, pieces produced. Selection tool this role in determining the quality and cost of production is part. Predicted forces from entering the tool are important. Experimental measurement of tool forces entered by the dynamometer is time consuming and expensive. For modeling machining finite element method (FEM) with fundamental criterion Johnson - Cook for Aluminum alloy 5083, software ABAQUS was used. In this paper rake angle, speed of cutting and force cutting during chip forming were discussed. Research shows that the simulation results are consistent with experiments. Simulation capability provided accurate predictions of forces into instruments for Aluminum alloy is 5083.

Study the Influence of Geometric Parameters on Springback in T-Section Aluminum Alloy Window Trim Strip Sheets Forming

2018 ◽  
Vol 920 ◽  
pp. 70-76 ◽  
Author(s):  
Bao Hang Zhu ◽  
Yi Xi Zhao ◽  
Zhong Qi Yu ◽  
Hui Yan
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Geometric Parameters ◽  
Finite Element Models ◽  
Quality Requirement ◽  
Forming Process ◽  
Assembly Quality ◽  
Simulation Results ◽  
In The Beginning ◽  
Springback Control

The T-section aluminum alloy window trim strip sheets are used to improve vehicle appearance. As the mobile scenery line, these window trim strips with claws need high forming accuracy to meet good assembly quality requirement. The top portion of the T-section sheet is stamped to form an edge flange structure. Springback control is essential in forming process. In this paper, the influence of the window trim strip geometric parameters on forming springback is studied. Some finite element models of the process were built with the Dynaform software. The simulation results were verified experimentally. The main conclusions include as belows: The different heights of the stiffeners part in T-section change the stiffness of the part. Although the stiffeners part does not participate in the forming, it also has springback in the forming process. So, it is necessary to study the influence of the flanging part width (W) and the stiffeners part height (H) of the T-section on springback. We set W to 15 mm and change the value of H value according to the real product. The value of springback increases with the increase of H value in the beginning. After ratio of H/W increases to 0.6, the value of springback fluctuates with the increase of H value. When ratio of H/W is about 0.5, the springback values are mostly less than ± 0.5 mm in key sections, which is acceptable.

Evaluation of Bevarage Can End Forming Process Using Kolmogorov’s Fracture Criterion

2017 ◽  
Vol 746 ◽  
pp. 3-9
Author(s):  
Vladimir G. Kolobov ◽  
Evgenii V. Aryshenskii ◽  
Yaroslav A. Erisov ◽  
Alexander Nam ◽  
Maksim S. Tepterev
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Stress State ◽  
Strain State ◽  
Fracture Criterion ◽  
Relative Elongation ◽  
Rolling Direction ◽  
Forming Process ◽  
Stress Strain

The present study investigates the process of beverage can end forming from 5182 aluminum alloy. Stress-strain state during forming is analyzed using finite element method in PAM-Stamp 2G, and fracturing probability is evaluated based on V.L. Kolmogorov’s fracture criterion. It is established, that stress state does not provide the sufficient plasticity margin during ends forming. Blank material plasticity resource is depleted during preliminary and reverse drawing stages, defects accumulation during countersink forming is negligible. Minimum relative elongation value, responsible for fracture-free end forming, is 6% in the rolling direction.

Effective Forming Processes of Hub Forging from Aluminum Alloy AlCu2SiMn

2013 ◽  
Vol 773-774 ◽  
pp. 115-118
Author(s):  
Andrzej Gontarz
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Material Flow ◽  
Theoretical Research ◽  
Material Consumption ◽  
Forming Process ◽  
Metal Forming Process ◽  
Large Material

This paper presents results of theoretical and experimental research works on metal forming process of a hub. A typical technology of forging on hammer of this part with flash was discussed. Two new processes of a hub forging were proposed, characterized by large material savings in comparison with typical technology. The first process is based on forming without flash of a forging with axial cavity. The second one is connected with forming of forging from pipe billet. The realization of these processes is possible at the application of a press with three movable working tools. Theoretical research works were done on the basis of simulations by means of finite element method. Simulations were made mainly in order to determine kinematics of material flow in forging processes and precision of shape and dimensions of obtained products. The first of the proposed processes was experimentally verified and a product of good quality was obtained. Material consumption of the analyzed processes and other factors acting on their effectiveness were also compared.

Numerical and Experimental Investigation of Bump Foil Forming Process for Foil Air Bearings

2011 ◽  
Vol 204-210 ◽  
pp. 2103-2108
Author(s):  
Wen Bo Duan ◽  
Hai Peng Geng ◽  
Bai Song Yang ◽  
Yan Hua Sun ◽  
Lie Yu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Deformable Body ◽  
Friction Model ◽  
Nonlinear Finite Element ◽  
Air Bearings ◽  
Forming Process ◽  
Rigid Plastic ◽  
Friction Forces ◽  
Simulation Results

In this paper, a simplified nonlinear finite element for bump foil forming process of foil air bearings is developed. The bump foil is dealt with as flexible deformable body, the upper die and lower die are considered as the rigid body without deformation. The friction model between bump foil and dies with velocity-dependent friction forces is described by arctan function. The forming process of SS304 Stainless Steel bump foil under different loads is investigated with rigid-plastic finite element method. The simulation results are compared with theoretical values and experimental results. Therefore more feasible process parameters are obtained to fabricate the bump foils.

scholarly journals Investigating of Mechanical Behavior of AA5083 in the Pressing Process Using Finite Element Analysis

2017 ◽  
Vol 11 (9) ◽  
pp. 51
Author(s):  
Babak Beglarzadeh ◽  
Behnam Davoodi
Keyword(s):  
Mechanical Properties ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Stress ◽  
Forming Process ◽  
Element Analysis ◽  
Cold Forming ◽  
Aluminum Alloy 5083 ◽  
And Control

The process of cold forming is considered of the most different industries and the use of such process in the manufacture of components and small parts has expanded. Therefore, analyzing the behavior of metals in this process to identify and control durability that is the main factor of limiting process has particular importance in industrial forming processes. In this study, cold forming process of aluminum metal has been studied and its effect on its mechanical properties has been evaluated. For this purpose, first modeling piece of aluminum alloy 5083 for cold forming process is carried out and using finite element analysis, mechanical properties of considered piece during cold forming processes are investigated. The results show that by reducing friction, stress and strain during the process will reduce, thereby durability of the piece increases, or in other words, ductile fracture occurs in longer life and higher stresses. The results show that by proper forming operations, it can be improved the strength and durability of aluminum alloy. Finally, validation of results, by comparing simulation results with experimental results is carried out.

Effective Forming Processes of Hub Forging from Aluminum Alloy AlCu2SiMn

2013 ◽  
Vol 572 ◽  
pp. 265-268
Author(s):  
Andrzej Gontarz
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Material Flow ◽  
Theoretical Research ◽  
Material Consumption ◽  
Forming Process ◽  
Metal Forming Process ◽  
Large Material

This paper presents results of theoretical and experimental research works on metal forming process of a hub. A typical technology of forging on hammer of this part with flash was discussed. Two new processes of a hub forging were proposed, characterized by large material savings in comparison with typical technology. The first process is based on forming without flash of a forging with axial cavity. The second one is connected with forming of forging from pipe billet. The realization of these processes is possible at the application of a press with three movable working tools. Theoretical research works were done on the basis of simulations by means of finite element method. Simulations were made mainly in order to determine kinematics of material flow in forging processes and precision of shape and dimensions of obtained products. The first of the proposed processes was experimentally verified and a product of good quality was obtained. Material consumption of the analyzed processes and other factors acting on their effectiveness were also compared.

Effect of Machining Parameters on Deformation Field in Machining by Finite Element Method

2011 ◽  
Vol 80-81 ◽  
pp. 942-945
Author(s):  
C.L. Wu ◽  
Z.R. Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Force ◽  
Large Strain ◽  
Effective Strain ◽  
High Hardness ◽  
Rake Angle ◽  
Machining Parameters ◽  
Cutting Velocity ◽  
Element Method

Formation of chip is a typical severe plastic deformation progress in machining which is only single deformation stage. The large strain, low temperature and deformation force are the major premises to create significant microstructure refinement in metals and alloys. A finite element method was developed to characterize the distribution of strain, temperature and cutting force. Effects of rake angle, cutting velocity and friction on effective strain, cutting force imposed in the chip are researched and the conditions which lead to the large stain deformation in machining are highlighted. The results of simulation have shown that chip materials with ultrafine grained and high hardness can be produced with negative tool rake angle at some lower cutting velocity.

Effects of Tool Rake Angle on the Curved Radius during Planing-Forming Process of Fine Heat Sink

2011 ◽  
Vol 317-319 ◽  
pp. 370-373 ◽  
Author(s):  
Liang Wei ◽  
Zhao Qin Yu ◽  
Le Le Zhang ◽  
Yong Jun Zhang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Residual Strain ◽  
Heat Sink ◽  
Rake Angle ◽  
Heat Sinks ◽  
Forming Process ◽  
New Process ◽  
Experiment Verification ◽  
Element Method

Planing-forming is a new process to machine fin heat sinks. This paper investigates the effects of the tool rake angle on the curved radius during planing-forming process by 2-D coupled thermo-mechanical finite element method and experiment verification. With the increasing of the tool rake angle from 0° to 30°, the curved radius increased. When the tool rake increased form 30°to 60°, the curved radius turned stable. After the chip displaced from the tool rake, the fin’s curling up due to the distribution gradient of the residual strain.

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