Numerical – Experimental Correlation of Sheet Hydroformed Component

2015 ◽  
Vol 651-653 ◽  
pp. 1140-1145
Author(s):  
Alessandro Spagnolo ◽  
Teresa Primo ◽  
Gabriele Papadia ◽  
Antonio del Prete
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Complex Geometry ◽  
Thickness Distribution ◽  
Fluid Pressure ◽  
Experimental Tests ◽  
Element Analysis ◽  
Influence Of Process Parameters ◽  
Experimental Correlation ◽  
Hydroforming Process

Sheet hydroforming has gained increasing interest in the automotive and aerospace industries because of its many advantages such as higher forming potentiality, good quality of the formed parts which may have complex geometry. The main advantage is that the uniform pressure can be transferred to any part of the formed blank at the same time. This paper reports numerical and experimental correlation for symmetrical hydroformed component. Experimental tests have been carried out through the hydroforming cell tooling, designed by the authors thanks to a research project, characterized by a variable upper blankholder load of eight different hydraulic actuators. The experimental tests have been carried out following a factorial plane of two factors, with two different levels for each factor and three replicates for each test with a total of 12 tests. In particular two process parameters have been considered: blank holder force, die fluid pressure. Each factor has been varied between an High (H) and Low level (L). The order in which have been conducted the tests has been established through the use of the Minitab software, in order to ensure the data normality and the absence of auto-correlation between the tests. An ANOVA analysis has been performed, in addition, with the aim of evaluating the influence of process parameters on the thickness distribution of the component, its formability and feasibility. Finally, finite element analysis (FEA) was used to understand the formability of a material during the hydroforming process. In this paper, the commercial finite element code LS-Dyna was used to run the simulations. A good numerical – experimental correlation has been obtained.

Finite Element Simulation and Experimental Research in Insulation Spacer Blanking

2014 ◽  
Vol 852 ◽  
pp. 523-528
Author(s):  
Qin Xiang Xia ◽  
Liang Bo Ji ◽  
Bao Hua Cao ◽  
You Xiang Li
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Analysis Model ◽  
Element Analysis ◽  
Influence Of Process Parameters ◽  
Metallic Material ◽  
Finite Element Analysis Model ◽  
Element Simulation

Blanking finite element analysis model of non-metallic material PET insulation spacer was established, and the influence of process parameters on blanking quality of insulation spacer was analyzed. The results show that the qualified cross-section quality, the high dimensional accuracy and the little bending distortion of blanking workpiece can be obtained by the reasonable blanking clearance and the higher blanking speed. The corresponding experiment was carried out, the results show that the process parameters of insulation spacer blanking obtained by numerical simulation are feasible, and the qualified insulation spacer was produced by the simulation results.

A Finite Element Model for Hydroforming Parts With Rigid Tolerances

1996 ◽  
Author(s):  
Jian An ◽  
A. H. Soni
Keyword(s):  
Finite Element ◽  
Simulation Model ◽  
Axial Force ◽  
Process Parameters ◽  
Fluid Pressure ◽  
Three Dimensional ◽  
Element Model ◽  
Tubular Part ◽  
Die Profile ◽  
Hydroforming Process

Abstract For many key process parameters in such a hydroforming hole piercing operation, the fluid pressure and the piercing force might be the most important process parameters that determine a quality of hydroformed parts. However, designing such process parameters is still arrived at based on extensive trial-and-error activities and experiences. This situation prevents the hydroforming technology from being adopted further even though the benefits of using hydroforming as an alternative to the conventional stamping is obvious. In this study a finite element based simulation model is developed to investigate the effects of process parameters in a tubular part hydroforming process. The process parameters includes fluid pressure path and axial force path and the curvature of die profile. A simulation model developed for the study is based on an explicit nonlinear finite element code and includes three dimensional modeling of die, blank tube and hole piercing punch. The behaviors of the fluid pressure, axial force and die profiles on the deformation of a complex tubular part are predicted and the design of such process variables is achieved.

Influence of Process Parameters on Spinning Force Using Finite Element Analysis and the Taguchi Method

2015 ◽  
Vol 659 ◽  
pp. 666-670
Author(s):  
Thanapat Sangkharat ◽  
Surangsee Dechjarern
Keyword(s):  
Finite Element ◽  
Taguchi Method ◽  
Process Parameters ◽  
Plastic Material ◽  
Element Analysis ◽  
Power Requirement ◽  
Influence Of Process Parameters ◽  
Roller Diameter ◽  
Spinning Process ◽  
Spinning Force

Metal spinning process is widely used for producing complex symmetry components. Main advantage of spinning process is a lower power requirement for large deformation with good surface finish. The aim of this paper is to investigate the influences of spinning process parameters, on spinning force. A three dimensional finite element model of the spinning process of SPCC sheet was successfully developed using elastic-plastic material property. The spinning experiments were carried out on a turning lathe and spinning forces were measure forces using a piezoelectric force transducer. The finite element prediction was compared with the experimental measurements and the results agreed well. Applying the Taguchi method, the effect of four process parameters, i.e. roller diameter, spindle speed, feed rate and feed depth, on spinning force were studied. The Taguchi main effect analysis and ANOVA results show that roller diameter and feed depth are the most important factor influencing the spinning force.

Analysis and Finite Element Method Simulation of Rear Sub-Frame Hydroforming Process

2011 ◽  
Vol 130-134 ◽  
pp. 191-194
Author(s):  
Zhou De Qu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Automotive Industry ◽  
Thickness Distribution ◽  
Tube Hydroforming ◽  
Finite Element Method Simulation ◽  
Element Analysis ◽  
Hydroforming Process ◽  
Deformation Behaviors ◽  
Element Method

The recent application of tube hydroforming in the automotive industry demands finite element analysis, since it is rapidly being used as an effective tool for the evaluation of the design of hydroforming processes. In this paper the formability of rear sub-frame in car body with tube hydroforming is studied. The comparison of various feeding and pressure on the hydroforming process is evaluated utilizing Finite Element Method to obtain detailed information on the deformation behaviors in hydroforming of rear sub-frame. It has been shown that optical leading paths such as axial feeding and internal pressure can quantify the circumferential thickness distribution in the rear sub-frame tube periphery.

scholarly journals Driving forces on dislocations: finite element analysis in the context of the non-singular dislocation theory

2021 ◽  
Author(s):  
Xiandong Zhou ◽  
Christoph Reimuth ◽  
Peter Stein ◽  
Bai-Xiang Xu
Keyword(s):  
Finite Element ◽  
Dislocation Loop ◽  
Driving Force ◽  
Complex Geometry ◽  
Driving Forces ◽  
Singular Solutions ◽  
Dislocation Model ◽  
Configurational Force ◽  
Element Analysis ◽  
Dislocation Configuration

AbstractThis work presents a regularized eigenstrain formulation around the slip plane of dislocations and the resultant non-singular solutions for various dislocation configurations. Moreover, we derive the generalized Eshelby stress tensor of the configurational force theory in the context of the proposed dislocation model. Based on the non-singular finite element solutions and the generalized configurational force formulation, we calculate the driving force on dislocations of various configurations, including single edge/screw dislocation, dislocation loop, interaction between a vacancy dislocation loop and an edge dislocation, as well as a dislocation cluster. The non-singular solutions and the driving force results are well benchmarked for different cases. The proposed formulation and the numerical scheme can be applied to any general dislocation configuration with complex geometry and loading conditions.

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