Optimization of Pre-Forging of the Aircraft Wheel Hub by FEM

2013 ◽  
Vol 652-654 ◽  
pp. 2029-2033
Author(s):  
Yan Yan Dai ◽  
Shi Qiang Lu ◽  
Ke Lu Wang ◽  
Shu Zhe Shang Guan
Keyword(s):  
Numerical Simulation ◽  
Effective Strain ◽  
Fem Simulation ◽  
The Finite Element Method ◽  
Forging Process ◽  
Mould Filling ◽  
Different Shapes ◽  
Deform 3D ◽  
Forging Load ◽  
Shape And Size

Optimization and design for shape and size of pre-forging with numerical simulation have some advantages compared with the conventional methods. The optimization object is the pre-forgings of an aircraft wheel hub. A commercially available software DEFORM 3D is used for the finite element method (FEM) simulation of the forging process of the aircraft wheel hub. The pre-forgings with three different shapes and sizes were used for numerical simulation. The effects of shape and size of the pre-forging on mould filling, forging load, effective strain and effective stress were analyzed. Finally, the suitable shape and size of the pre-forging were obtained based on the numerical simulation results.

Optimization of the Hot Forming Processes for the Connecting Rod

2012 ◽  
Vol 461 ◽  
pp. 721-724
Author(s):  
Xia Chen ◽  
Yang Yi ◽  
Qing Ming Chang ◽  
Yun Xiang Zhang ◽  
Sheng Liu
Keyword(s):  
Stress Field ◽  
Effective Stress ◽  
Strain Field ◽  
Effective Strain ◽  
Three Dimensional ◽  
Fem Simulation ◽  
Connecting Rod ◽  
3D Fem ◽  
Forging Process ◽  
Deform 3D

A three-dimensional thermo-mechanically coupled FEM-simulation of the production of a connecting rod has been performed between dies (pre- and final-forging). According to the part’s characters and its dimensions, a hammer die forging process was determined. According to the hammer die process, three-dimensional connecting nod model was built in UG software and two different cases for pre-forging was designed. Different forming case was simulated by Deform-3D FEM program, the effective stress field and effective strain field were analyzed by comparison; it proved that optimized performing process was reasonable and can be used as reference in production.

Modeling and Numerical Simulation Research on Hollow Steel Ingot Forging Process of Heavy Cylinder Forging

2013 ◽  
Vol 712-715 ◽  
pp. 627-632
Author(s):  
Min Liu ◽  
Qing Xian Ma
Keyword(s):  
Numerical Simulation ◽  
Grain Size ◽  
Shear Zone ◽  
Grain Refinement ◽  
Steel Ingot ◽  
Effective Strain ◽  
Meridian Plane ◽  
Forging Process ◽  
Forming Load ◽  
Average Grain Size

Aiming at the disadvantages of low utilization ratio of steel ingot, uneven microstructure properties and long production period in the solid steel ingot forging process of heavy cylinder forgings such as reactor pressure vessel, a new shortened process using hollow steel ingot was proposed. By means of modeling of lead sample and DEFORM-3D numerical simulation, the deformation law and grain refinement behavior for 162 ton hollow steel ingot upsetting at different reduction ratios, pressing speeds and friction factors were investigated, and the formation rule of inner-wall defects in upsetting of hollow steel ingots with different shape factors was further analyzed. Simulation results show that the severest deformation occurs in the shear zone of meridian plane in the upsetting process of hollow steel ingot, and the average grain size in the shear zone is the smallest. As pressing speed increases, the forming load gradually increases and the deformation uniformity gets worse, while the average grain size decreases. An increase in friction factor can increase the peak value of effective strain, but it significantly reduces the deformation uniformity, increases the forming load and goes against grain refinement. Moreover, the four kinds of defects on the inner wall of steel ingot can be eliminated effectively by referring to the plotted defect control curve for hollow steel ingot during high temperature upsetting.

Numerical Simulation Analysis on Cold Closed-Die Forging of Differential Satellite Gear in Car

2008 ◽  
Vol 575-578 ◽  
pp. 517-524 ◽  
Author(s):  
Yao Zong Zhang ◽  
Jian Bo Huang ◽  
Xue Lin ◽  
Quan Shui Fang
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Simulation Software ◽  
Bevel Gear ◽  
Cold Forging ◽  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
Forming Defects ◽  
Deform 3D

The cold closed-die forging process of the gear is a kind of new technique of the precise forming of gear in recent years. In this paper, the cold closed-die forging process of differential satellite gear in car was analyzed through numerical simulation method. Forming mold was designed with Pro/E Wildfire2.0 which included four components : upper punch, lower punch, tooth shape upper die and lower die for Normal Cone. The three-dimensional models of satellite bevel gear mould were built and imported into numerical simulation software DEFORM-3D. Because the gear has the uniform circumferential features, in order to save time and improve the accuracy, only one tooth was simulated, and the full simulation outcome of 10 teeth was mirrored from this one. Through the numerical simulation analysis of DEFORM-3D, the instantaneous deformation and stress filed were gained. Forming defects were forecasted and the cold closed-die forging rule for satellite gear used in car was obtained which can provide effective references for no-flash cold forging process of planet bevel gear and the mold design.

Study on Internal Helical Gear Worm Forging by Finite Element Analysis

2013 ◽  
Vol 465-466 ◽  
pp. 1361-1364
Author(s):  
Tung Sheng Yang ◽  
Jia Yu Deng ◽  
Jie Chang
Keyword(s):  
Finite Element ◽  
Strain Distribution ◽  
Effective Strain ◽  
Helical Gear ◽  
The Finite Element Method ◽  
Forming Force ◽  
Element Analysis ◽  
Power Requirement ◽  
Warm Forging ◽  
Forging Load

This study applies the finite element method (FEM) to predict maximum forging load and effective strain in internal helical gear forging. Maximum forging load and effective strain are determined for different process parameters, such as modules, number of teeth, and die temperature of the internal helical gear forging, using the FEM. Finally, the prediction of the power requirement for the internal helical gear warm forging is determined. Therefore, the maximum forming force and strain distribution will be prediction for the different parameters of helical gear worm forging.

FEM Simulation on Rotating Piercing Process with Coulomb Friction

2013 ◽  
Vol 284-287 ◽  
pp. 127-131
Author(s):  
Hsiang Yu Teng ◽  
Gow Yi Tzou ◽  
Yeong-Maw Hwang
Keyword(s):  
Coulomb Friction ◽  
Effective Strain ◽  
Fem Simulation ◽  
Frictional Coefficient ◽  
Work Piece ◽  
Shearing Force ◽  
Fem Model ◽  
Blank Holder ◽  
Inner Diameter ◽  
Deform 3D

This study proposes a new piercing technology with rotating punch; it carries out an FEM simulation on rotating piercing process using DEFORM-3D commercial software. Frictions among the punch, the blank holder, the dies and the work-piece material are assumed as Coulomb friction, but can be different. The surface of the inner diameter, the effective stress, the effective strain, velocity field, damage, burr and the shearing force can be determined form the FEM simulation. In this study, effects of various piercing conditions such as the clearance, the punch nose angle, the frictional coefficient, the rotating angular velocity, the shearing force, and burr on shearing characteristics are explored effectively to realize the feasibility of FEM model.

The Improvement and Finite Element Analysis of Large Crankshaft Forging Process

2013 ◽  
Vol 365-366 ◽  
pp. 561-564
Author(s):  
Jian Jun Wang ◽  
Su Lan Hao ◽  
Lu Pan ◽  
Yan Ming Zhang
Keyword(s):  
Numerical Simulation ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Simulation Software ◽  
Die Design ◽  
Element Analysis ◽  
Forging Process ◽  
Large Load ◽  
Deform 3D

In view of large load, the shape of large crank forgings and forging process are designed reasonably. Large crank forging process is simulated by numerical simulation software DEFORM-3D to improve the forging process and the dies, including adding upsetting step and related dies. The result shows that improved process and dies can obtain higher quality finish forgings and the load reduces to a rational level, which provides basis for crank forging process and die design.

Study on the Maximum Forging Load and Final Face Width of Powder Spur Gear Forging

2011 ◽  
Vol 697-698 ◽  
pp. 420-423
Author(s):  
Tung Sheng Yang ◽  
J.Y. Li ◽  
C. Y. Liu
Keyword(s):  
Fem Simulation ◽  
Spur Gear ◽  
Density Variation ◽  
Power Requirement ◽  
Forging Process ◽  
Complete Filling ◽  
Face Width ◽  
Complicated Geometry ◽  
Forging Force ◽  
Forging Load

Powder forging combines powder metallurgy and forging technology, thus possess the advantages of both processes that result in both stronger and yet more versatile products with complicated geometry and arbitrary alloy compositions. For complete filling up, predicting the power requirement and final face width is an important feature of the powder forging process. In this paper, a finite element method is used to investigate the forging force, the final face width and the density variation of the spur gear powder forging process. In order to verify the FEM simulation results, the experimental data are compared with the results of the current simulation for the forging force and the final face width of spur gear. The influences of the parameters such as modules, number of teeth, the initial relative density, the ratio of the height to diameter of billet and friction factor on the forging force and the final face width of the billets are also examined.

Numerical Simulation of Equal Channel Angular Pressing for Multi-Pass in Different Routes

2012 ◽  
Vol 268-270 ◽  
pp. 373-377 ◽  
Author(s):  
Xiao Lian Zhao ◽  
Na Chen ◽  
Ning Ning Zhao
Keyword(s):  
Numerical Simulation ◽  
Equal Channel Angular Pressing ◽  
Effective Stress ◽  
Pure Aluminum ◽  
Effective Strain ◽  
Angular Pressing ◽  
3D Software ◽  
Deform 3D

In order to investigate the effect of continued equal channel angular pressing (ECAP) with different routes and passes on the homogeneity of structure, the process of continued ECAP for pure aluminum bar was simulated by DEFORM-3D software. It obtains the load-stroke curves for different passes, distribution of effective stress and effective strain in different routes after the sample is extruded eight passes by ECAP in routes A, BC and C. The results show that the uniformity of the sample is improved with the increase of passes. The microstructure of specimen which is extruded in route BC is the most uniform, but it is the worst in route A.

Optimisation of Tubular Hydroforming Processes for Wrinkling and Thinning Control

2011 ◽  
Vol 473 ◽  
pp. 159-167
Author(s):  
João F.M. Caseiro ◽  
Robertt Angelo Fontes Valente ◽  
António Andrade-Campos ◽  
Renato Natal Jorge
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Differential Evolution ◽  
Fem Simulation ◽  
Design Tool ◽  
The Finite Element Method ◽  
Combined Procedure ◽  
Metallic Parts ◽  
Optimisation Procedure

This paper is focused on the development and implementation of an innovative optimisation algorithm for the wrinkling and thinning control during the hydroforming of complex metallic parts. A straightforward numerical algorithm for simultaneous tracking and evaluation of the initiation of wrinkling/thinning defects was implemented, together with a numerical simulation program based on the Finite Element Method (FEM). After undesirable wrinkling/thinning patterns are identified during FEM simulation, the developed optimisation procedure (called Hybrid Differential Evolution Particle Swarm Optimisation - HDEPSO) is responsible to automatically correct the process input parameters, in order to achieve the successful forming of the desired part. In the end, the combined procedure (optimisation methodology + FEM) proved to be able to lead to a suitable numerical simulation and design tool for industrial hydroformed metallic tubular parts.

scholarly journals Establishment and Application of the Void Closure Prediction Model of 316LN

2020 ◽  
Vol 2020 ◽  
pp. 1-7
Author(s):  
Min Qin ◽  
Jiansheng Liu ◽  
Jingdan Li
Keyword(s):  
Stainless Steel ◽  
Prediction Model ◽  
Large Scale ◽  
Effective Strain ◽  
Fem Simulation ◽  
Closure Model ◽  
Forming Process ◽  
Void Closure ◽  
Forging Process ◽  
316Ln Stainless Steel

The presence of voids in the ingot affects the mechanical properties of the final products of the forging process. It is essential to establish a void closure model to predict cavity closure in the forging process to optimize the forging process and improve forging quality. The main purpose of this study is to obtain an accurate prediction model of void closure for 316LN stainless steel. Using the FEM simulation method to study the closure of spherical voids during forging compression of 316LN materials, we can accurately characterize the state of void closure. The void closure ratio K under different deformations at 1,200°C was counted, and the relationship between K and the effective strain was established to obtain the void closure prediction model of 316LN stainless steel. The void closure prediction model is implanted into DEFORM software through the secondary development method to generate the void closure ratio K. In the postprocessing module of DEFORM software, the void closure status of each part during the forming process can be directly observed. Comparing the results of large-scale upsetting experiments and simulation results, the closure error of each part was only 3%, which indicates that the void closure model established in this paper has higher accuracy, which is helpful for the optimization of the forging process and the control of forging quality.

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