Velocity Optimization on Squashing and Bending Process of Large Diameter Elbow

2011 ◽  
Vol 194-196 ◽  
pp. 2204-2208
Author(s):  
Jian Zhang ◽  
Tong Mei Xiao ◽  
Liang Chu ◽  
Da Sen Bi
Keyword(s):  
Process Parameters ◽  
Large Diameter ◽  
Second Step ◽  
Fem Simulations ◽  
Bending Process ◽  
Simulation Results

FEM simulations of squashing and bending process of large diameter elbow was applied to analyze the influence of squashing velocities, one of the key process parameters, on the deformation of the tube. In this study the squashing distance of first step is 300mm after several simulation attempts, corresponding to different squashing speeds and different bending velocities of second step. The simulation results of different velocities are compared and discussed. In the end the final velocities of the two steps are given.

Optimization of Pipe Induction Bending Process Parameters

2017 ◽  
Author(s):  
T. S. Kathayat ◽  
Rajesh K. Goyal ◽  
Richard Hill ◽  
Tushal Kyada
Keyword(s):  
Induction Heating ◽  
Process Parameters ◽  
Water Pressure ◽  
Large Diameter ◽  
Water Flow Rate ◽  
Microstructural Analysis ◽  
Mechanical Tests ◽  
Complex Process ◽  
Bending Process ◽  
Bending Radius

Hot pushed induction heating is a bending process used to bend pipes having a small bending radius with a large diameter. This is a complex process since it involves mechanical process of bending and thermal process of localized induction heating. This paper deals with the optimization of induction bending process parameters such as bending speed, water flow rate, water pressure, air pressure and induction coil to water coil distance. Mother pipes of size 464 mm OD × 20.60 mm and grade API 5L X65MS/MO were used to make trial bends of 5D radius in 30° angle. Trial bends were subjected to mechanical tests and microstructural analysis to evaluate the effects of selected process parameters.

Experimental and Numerical Investigation on Filling Roll Bending of Aluminum Alloy Integral Panel

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Han Xiao ◽  
Shi-hong Zhang ◽  
Jin-song Liu ◽  
Ming Cheng ◽  
Hong-xi Liu
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Numerical Methods ◽  
Process Parameters ◽  
Element Model ◽  
Geometric Accuracy ◽  
Roll Bending ◽  
Bending Process ◽  
Simulation Results ◽  
Deformation Homogeneity

Integral panels are widely used in aerospace industries. A filling roll bending process is proposed to form integral panels. Filling roll bending experiments of aluminum alloy integral panels were carried out. A 3D elastic–plastic finite element model of filling roll bending process was established and validated by experiment. The effects of filler and process parameters on the deformation homogeneity of the panels were analyzed by using experimental and numerical methods. The results indicate that the filler can improve the deformation homogeneity. With the increasing of the displacement of the top-roller from 5 mm to 40 mm, the experimental and simulation bending radii with filler all reduce, the experimental results reduce from 5806 mm to 190 mm, the simulation results reduce from 5924 mm to 199 mm, and the simulation springback rates with filler reduce from 0.92% to 0.15%. It is proved that high geometric accuracy of the integral panels can be obtained by using filling roll bending process.

scholarly journals The influence of freeform bending process parameters on residual stresses for steel tubes

2021 ◽  
pp. 100047
Author(s):  
Daniel Maier ◽  
Sophie Stebner ◽  
Ahmed Ismail ◽  
Michael Dölz ◽  
Boris Lohmann ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Process Parameters ◽  
Steel Tubes ◽  
Bending Process

scholarly journals Verification of electric steel punching simulation results using microhardness

2021 ◽  
Author(s):  
Sampsa Vili Antero Laakso ◽  
Ugur Aydin ◽  
Peter Krajnik
Keyword(s):  
Plastic Deformation ◽  
High Speed ◽  
Steel Sheet ◽  
Electrical Steel ◽  
High Speed Steel ◽  
Experimental Methods ◽  
Fem Simulations ◽  
Iron Losses ◽  
Simulation Results ◽  
Electrical Steel Sheet

AbstractOne of the most dominant manufacturing methods in the production of electromechanical devices from sheet metal is punching. In punching, the material undergoes plastic deformation and finally fracture. Punching of an electrical steel sheet causes plastic deformation on the edges of the part, which affects the magnetic properties of the material, i.e., increases iron losses in the material, which in turn has a negative effect on the performance of the electromagnetic devices in the final product. Therefore, punching-induced iron losses decrease the energy efficiency of the device. FEM simulations of punching have shown significantly increased plastic deformation on the workpiece edges with increasing tool wear. In order to identify the critical tool wear, after which the iron losses have increased beyond acceptable limits, the simulation results must be verified with experimental methods. The acceptable limits are pushed further in the standards by the International Electrotechnical Commission (IEC). The new standard (IEC TS 60034-30-2:2016) has much stricter limits regarding the energy efficiency of electromechanical machines, with an IE5 class efficiency that exceeds the previous IE4 class (IEC 60034-30-1:2014) requirements by 30%. The simulations are done using Scientific Forming Technologies Corporation Deform, a finite element software for material processing simulations. The electrical steel used is M400-50A, and the tool material is Vanadis 23, a powder-based high-speed steel. Vanadis 23 is a high alloyed powder metallurgical high-speed steel with a high abrasive wear resistance and a high compressive strength. It is suitable for cold work processing like punching. In the existing literature, FEM simulations and experimental methods have been incorporated for investigating the edge deformation properties of sheared surfaces, but there is a research gap in verifying the simulation results with the experimental methods. In this paper, FEM simulation of the punching process is verified using an electrical steel sheet from real production environment and measuring the deformation of the edges using microhardness measurements. The simulations show high plastic deformation 50 μm into the workpiece edge, a result that is shown to be in good agreement with the experimental results.

Numerical Analysis on the Extruded Volume and Length Ratios of Backward Tube to Forward Rod in Combined Extrusion Processes

2006 ◽  
Vol 519-521 ◽  
pp. 919-924 ◽  
Author(s):  
B.S. Ham ◽  
J.H. Ok ◽  
Jung Min Seo ◽  
Beong Bok Hwang ◽  
K.H. Min ◽  
...  
Keyword(s):  
Process Parameters ◽  
Material Flow ◽  
Volume Ratio ◽  
Forward Direction ◽  
Extrusion Process ◽  
Forming Load ◽  
Tube Extrusion ◽  
Corner Radius ◽  
Combined Operation ◽  
Simulation Results

This paper is concerned with forward rod extrusion combined simultaneously with backward tube extrusion process in both steady and transient states. The analysis has been conducted in numerical manner by employing a rigid-plastic finite element method. AA 2024 aluminum alloy was selected as a model material for analysis. Among many process parameters, major design factors chosen for analysis include frictional condition, thickness of tube in backward direction, punch corner radius, and die corner radius. The main goal of this study is to investigate the material flow characteristics in combined extrusion process, i.e. forward rod extrusion combined simultaneously with backward tube extrusion process. Simulation results have been summarized in term of relationships between process parameters and extruded length and volume ratios, and between process parameters and force requirements, respectively. The extruded length ratio is defined as the ratio of tube length extruded in backward direction to rod length extruded in forward direction, and the volume ratio as that of extruded volume in backward direction to that in forward direction, respectively. It has been revealed from the simulation results that material flow into both backward and forward directions are mostly influenced by the backward tube thickness, and other process parameters such as die corner radius etc. have little influence on the volume ratio particularly in steady state of combined extrusion process. The pressure distributions along the tool-workpiece interface have been also analyzed such that the pressure exerted on die is not so significant in this particular process such as combined operation process. Comparisons between multi-stage forming process in sequence operation and one stage combined operation have been also made in terms of forming load and pressure exerted on die. The simulation results shows that the combined extrusion process has the greatest advantage of lower forming load comparing to that in sequence operation.

A Two Step Damage Prognosis Method for Beam-Like Truss Structures

2014 ◽  
Vol 578-579 ◽  
pp. 1092-1095
Author(s):  
Hao Kai Jia ◽  
Ling Yu
Keyword(s):  
Finite Element Method ◽  
Strain Energy ◽  
Truss Structure ◽  
Truss Structures ◽  
Second Step ◽  
The Finite Element Method ◽  
Modal Strain Energy ◽  
Damage Prognosis ◽  
Modal Curvature ◽  
Simulation Results

In this study, a two step damage prognosis method is proposed for beam-like truss structures via combining modal curvature change (MCC) with modal strain energy change ratio (MSECR). Changes in the modal curvature and the elemental strain energy are selected as the indicator of damage prognosis. Different damage elements with different damage degrees are simulated. In the first step, the finite element method is used to model a beam-like truss structure and the displacement modes are got. The damage region is estimated by the MCC of top and bottom chords of a beam-like truss structure. In the second step, the elemental MSECR in the damage region is calculated and the maximum MSECR element is deemed as the damage element. The simulation results show that this method can accurately locate the damage in the beam-like truss structure.

Simulation Investigation of Tangential-Feed Centerless Grinding Process Performed on Surface Grinder

2009 ◽  
Vol 626-627 ◽  
pp. 23-28
Author(s):  
Wei Xing Xu ◽  
Yong Bo Wu ◽  
Takashi Sato ◽  
Wei Min Lin
Keyword(s):  
Elastic Deformation ◽  
Process Parameters ◽  
Simulation Method ◽  
Machining Accuracy ◽  
Grinding Process ◽  
Elasticity Parameter ◽  
Grinding Method ◽  
Centerless Grinding ◽  
Simulation Results ◽  
Grinding Technique

In our previous study, a new centerless grinding method using surface grinder was proposed. This paper describes a simulation method for investigating the workpiece rounding process in which a model taking the elastic deformation of the machine into consideration is created, and revealing how the process parameters affect the machining accuracy in the new grinding technique. In addition, a practice way to determine the machining-elasticity parameter showing the elastic deformation is developed. The simulation results are compared to show the effect of process parameters on the machining accuracy.

Large-Diameter Line Pipe Expanding Process

2012 ◽  
Vol 192 ◽  
pp. 180-184 ◽  
Author(s):  
Ai Xia He ◽  
Rong Chang Li
Keyword(s):  
Process Parameters ◽  
Large Diameter ◽  
Dimensional Accuracy ◽  
Optimization Method ◽  
Main Process ◽  
Shape Accuracy ◽  
Line Pipe ◽  
Factors Affecting ◽  
Array Optimization

Mechanical expanding process for large diameter line pipe, a detailed analysis of factors affecting the quality of the final products of the mechanical expansion and proposed optimization using orthogonal array optimization method, as an indicator of dimensional accuracy and shape accuracy of the products, combination of a variety of specifications of mechanical expanding products, the main process parameters to be optimized. Analysis and discussion of results, revealing the degree of influence of various factors on the quality of the final product, and gives the optimum combination of the results. Experiments show that the combination of optimized process parameters, and more help to improve the accuracy of the size and shape of products.

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