FEM Simulation of Multi-Stage Forging for Dray Fasteners

2020 ◽  
Vol 830 ◽  
pp. 1-8 ◽  
Author(s):  
Un Chin Chai ◽  
Gow Yi Tzou ◽  
Chao Ming Hsu ◽  
Shang Ping Wei
Keyword(s):  
Effective Strain ◽  
Fem Simulation ◽  
Assembly Model ◽  
Multi Stage ◽  
Solid Models ◽  
Assembly Drawing ◽  
Three Stages ◽  
Forging Force ◽  
Realistic Experiment ◽  
Good Agreement

This study uses the dies of the dray fasteners processing graphics provided by the fastener’s industry to establish 3D dies and components solid models based on the embedded drawing function tools provided by the component model (Standard.ipt) of Autodesk Inventor CAD software. After finishing the dies and components drawing, the integrated assembly drawing of dies can be obtained through the assembly model (Standard.iam) firstly. Three stages forming processes can be conducted and carried out the FEM simulation to check the forming acceptance. The effective stress, the effective strain, the velocity field, and the forging force can be obtained by the FEM simulation. Moreover, the realistic experiment can be performed to verify the acceptance of FEM simulation. The dimensions of final product can be measured to get the errors between FEM and experiment. It is noted that the errors show a good agreement with the experiment.

FEM Simulation and Experimental Verification on Rotating Compression Forming of Double-Layer Clad Ring Considering Shear Friction

2015 ◽  
Vol 764-765 ◽  
pp. 280-284 ◽  
Author(s):  
Gow Yi Tzou ◽  
Yeong Maw Hwang ◽  
Hsiang Yu Teng
Keyword(s):  
Double Layer ◽  
Effective Strain ◽  
Fem Simulation ◽  
Compression Force ◽  
Free Surfaces ◽  
Simulation Based ◽  
Shear Friction ◽  
Deform 3D ◽  
Realistic Experiment ◽  
Good Agreement

This study uses FEM simulation based on Deform 3D commercial software to explore the plastic behaviors in the rotating compression of double-layer bounded clad ring under constant shear friction. The effective stress, the effective strain, the velocity field, the compression force under various forming conditions can be determined from FEM simulation. The realistic experiment has been performed to verify the acceptance of FEM simulation. From the comparisons, the compression force and free surfaces of outer and inner diameters shows a good agreement with the experiments, it proves the FEM simulation can be accepted as industry references.

scholarly journals Generalized optimizations of two-stage forging of micro/meso copper fastener

2018 ◽  
Vol 185 ◽  
pp. 00002
Author(s):  
Shih-Hsien Lin ◽  
Un-Chin Chai ◽  
Gow-Yi Tzou ◽  
Dyi-Cheng Chen
Keyword(s):  
Simulation Analysis ◽  
Effective Strain ◽  
Cold Forging ◽  
Two Stage ◽  
Forming Simulation ◽  
Multi Stage ◽  
Element Simulation ◽  
Die Stress ◽  
Stress Optimization ◽  
Forging Force

Three are generalized simulation optimizations considering the forging force, the die stress, and the dual-goals in two-stage forging of micro/meso copper fastener. Constant shear friction between the dies and workpiece is assumed to perform multi-stage cold forging forming simulation analysis, and the Taguchi method with the finite element simulation has been used for mold-and-dies parameters design simulation optimizations considering the forging force, die stress, and dual-goals. The die stress optimization is used to explore the effects on effective stress, effective strain, velocity field, die stress, forging force, and shape of product. The influence rank to forging process of micro/meso copper fastener for three optimizations can be determined, and the optimal parameters assembly consider die stress can be obtained in this study. It is noted that the punch design innovation can reduce the forging force and die stress.

FEM Simulation and Experimental Verification on Rotating Forging of Three-Layer Clad Cylinder Considering Constant Shear Friction

2012 ◽  
Vol 602-604 ◽  
pp. 2214-2218
Author(s):  
Gow Yi Tzou
Keyword(s):  
Finite Element ◽  
Velocity Field ◽  
Effective Strain ◽  
Fem Simulation ◽  
Interface Friction ◽  
Finite Element Software ◽  
Constant Shear ◽  
Element Simulation ◽  
Shear Friction ◽  
Forging Force

This study assumes the interface friction between dies and bounded three-layer clad cylinder as constant shear friction considering the rotation of three-layer bounded clad cylinder to establish the finite element simulation. The commercial finite element software (SUPERFORM) is used to explore effectively the effective stress, effective strain, and velocity field, forging force, and rotating torque in the three-layer clad cylinder rotating forging. Moreover, the rotating forging experiment of the three-layer clad cylinder is carried out practically to measure the forging force and the outer surface of three-layer clad cylinder. Forging force between analysis and experiment are compared to verify the acceptance of FEM simulation. This study can be offered to industries for technology establishment of rotating forging.

Optimization of Forging Preforms by Using Pseudo Inverse Approach

2012 ◽  
Vol 504-506 ◽  
pp. 613-618 ◽  
Author(s):  
Ali Halouani ◽  
Y.M. Li ◽  
Boussad Abbès ◽  
Y.Q. Guo ◽  
F.J. Meng ◽  
...  
Keyword(s):  
Effective Strain ◽  
Equivalent Stress ◽  
Optimization Method ◽  
Final Part ◽  
Cold Forging ◽  
Inverse Approach ◽  
Multi Stage ◽  
Optimization Loop ◽  
Forging Force ◽  
Pseudo Inverse

A simplified method called “Pseudo Inverse Approach” (PIA) has been developed for axi-symmetrical cold forging modelling. The approach is based on the knowledge of the final part shape. Some intermediate configurations are introduced and corrected by using a free surface method to consider the deformation paths without classical contact treatment. A new direct algorithm of plasticity is developed using the notion of equivalent stress and the tensile curve, which leads to a very fast and robust plastic integration procedure. Numerical tests have shown that the Pseudo Inverse Approach is very fast compared to the incremental approach. In this paper, the PIA will be used in an optimization loop for the preliminary preform design in multi-stage forging processes. The optimization problem is to minimize the effective strain variation in the final part and the maximum forging force during the forging process. The numerical results of the optimization method using the PIA are compared to those using the classical incremental approaches to show the efficiency and limitations of the PIA.

Study on Multi-Stage Cold Forging of Stainless Automotive Battery Fastener

2013 ◽  
Vol 284-287 ◽  
pp. 211-215
Author(s):  
Ming Chao Sun ◽  
Gow Yi Tzou ◽  
Liang An Zheng
Keyword(s):  
Error Rate ◽  
Effective Strain ◽  
Cold Forging ◽  
Fourth Stage ◽  
Future Production ◽  
Multi Stage ◽  
Measurement Results ◽  
The Future ◽  
3D Software ◽  
Forging Force

Stainless automotive battery fastener requires high dimension precision and narrow tolerance. In order to save the developing cost and accumulate more production design experiences, CAD/CAE technology has been used in multi-stage cold forging with five stages to shorten our developing cycle time. In this paper, the CAD drawing is made by Inventor 3D software, then import the STL file to DEFORM-3D software to do the settings of pre-process and simulation analysis. Effective stress, effective strain, velocity field, and forging force have been shown in this study. Finally, the actual manufacture measurement results compares with simulation datum to verify the analysis acceptance. After comparing the FEM simulation results with actual forming measurements, the error rate of washer diameter is increased in fourth stage. Although the measurement results are still in tolerance, the future work is to decrease the error rate through optimizing the mold design of fourth stage. The verification is performed to reduce the error rate according to the research method proposed in the study. On the other hand, the mold life in the actual forming is found to be easily damaged in the fifth stage. In the future, production improvement should be done through modifying the design of mold and die for the third and the fourth stages, the life of mold and die is explored to reduce the forging force in the fifth stage.

scholarly journals 3D-FEM Simulation of Hot Rolling Process and Characterization of the Resultant Microstructure of a Light-Weight Mn Steel

Crystals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 569
Author(s):  
Ana Claudia González-Castillo ◽  
José de Jesús Cruz-Rivera ◽  
Mitsuo Osvaldo Ramos-Azpeitia ◽  
Pedro Garnica-González ◽  
Carlos Gamaliel Garay-Reyes ◽  
...  
Keyword(s):  
Hot Rolling ◽  
Thermomechanical Processing ◽  
Computational Simulation ◽  
Effective Strain ◽  
Fem Simulation ◽  
Rolling Process ◽  
3D Fem ◽  
Hot Rolling Process ◽  
Mn Steel

Computational simulation has become more important in the design of thermomechanical processing since it allows the optimization of associated parameters such as temperature, stresses, strains and phase transformations. This work presents the results of the three-dimensional Finite Element Method (FEM) simulation of the hot rolling process of a medium Mn steel using DEFORM-3D software. Temperature and effective strain distribution in the surface and center of the sheet were analyzed for different rolling passes; also the change in damage factor was evaluated. According to the hot rolling simulation results, experimental hot rolling parameters were established in order to obtain the desired microstructure avoiding the presence of ferrite precipitation during the process. The microstructural characterization of the hot rolled steel was carried out using optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). It was found that the phases present in the steel after hot rolling are austenite and α′-martensite. Additionally, to understand the mechanical behavior, tensile tests were performed and concluded that this new steel can be catalogued in the third automotive generation.

scholarly journals The impact of nonresponse in different survey stages on the precision of prevalence estimates for multi-stage survey studies

2021 ◽  
Vol 14 (1) ◽  
Author(s):  
Ming Ma ◽  
Sophie Rosenberg ◽  
Alexander M. Kaizer
Keyword(s):  
Survey Research ◽  
State Level ◽  
Simulation Approach ◽  
Multi Stage ◽  
Margin Of Error ◽  
Prevalence Estimates ◽  
Three Stages ◽  
Nonresponse Rate ◽  
The Mean ◽  
The Impact

Abstract Objective While it is known that nonresponse might produce biased results and impair the precision of results in survey research studies, the pattern of the impact on the precision of estimates due to the nonresponse in different survey stages is historically overlooked. Having this type of information is essential when creating recruitment plans. This study proposes to examine and compare the effect of nonresponse in different stages on the precision of prevalence estimates in multi-stage survey studies. Based on data from a state level survey, a simulation approach was used to generate datasets with different nonresponse rates in three stages. The margin of error was then compared between the datasets with nonresponse at three different survey stages for 12 outcomes. Results At the same nonresponse rate, the mean margin of error was greater for the data with nonresponse at higher stages. Additionally, as the nonresponse rate increased, precision was more inflated within the data with higher stage nonresponse. This suggests that the effort used to recruit the primary sampling units is more crucial to improve the precision of estimates in multi-stage survey studies.

scholarly journals Forming parameters optimizations with drawing force and die stress in wire rod drawing using rotating die under Coulomb friction

2018 ◽  
Vol 185 ◽  
pp. 00025
Author(s):  
Ing-Kiat Tiong ◽  
Un-Chin Chai ◽  
Gow-Yi Tzou
Keyword(s):  
Taguchi Method ◽  
Coulomb Friction ◽  
Effective Strain ◽  
Fem Simulation ◽  
Frictional Coefficient ◽  
Simulation Software ◽  
Drawing Force ◽  
Wire Rod ◽  
Forming Parameters ◽  
Die Stress

An optimization research is performed on the related forming parameters of wire rod drawing through a rotating die under Coulomb friction. The optimization research is conducted through finite element method (FEM) simulation combined with Taguchi method. There are two drawing characteristic optimizations have been carried out. They are the optimizations with drawing force and die stress. The forming parameters considered in this study are half die angle, frictional coefficient, die fillet, and rotating angular velocity of the rotating die. The same procedure is carried out in both optimizations. The geometrical models of the wire rod, top die and rotating die are constructed firstly in SolidWorks and imported into the FEM simulation software named DEFORM 3D. With the aid of Taguchi method, the simulation experiments are carried out. The results such as drawing force, die stress, and the corresponding signal-to-noise (S/N) ratio are obtained and compared. The influence rank of the forming parameters and the optimal combination of parameters are obtained through the response table for both optimizations. The results such as effective stress, effective strain, velocity field, drawing force, and die stress are studied. The results show that the minimizations of drawing force and die stress are successfully achieved.

Estimation of Strain-Hardness Correlation in Cold-Forged Austenitic Stainless Steel

2014 ◽  
Vol 622-623 ◽  
pp. 179-185 ◽  
Author(s):  
Piotr Skubisz ◽  
Maciej Rumiński ◽  
Łukasz Lisiecki
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Strain Hardening ◽  
Effective Strain ◽  
Cold Deformation ◽  
Metal Flow ◽  
Fem Simulation ◽  
Large Head ◽  
The Relationship

The paper presents selected aspects of analysis cold micro-forging process of a screw made of austenitic stainless steel, concerning relation between strain and hardness. Strain hardening character of a material in consecutive forming operations was analyzed experimentally by the measurement of hardness distribution made on longitudinal axial sections of screws. The relationship between hardness and effective strain (hardness curve) was determined, which made it possible to obtain strain distributions in different regions of a material subjected to cold deformation on the basis of strain distribution numerically estimated with FEM simulation performed using QForm2D/3D commercial software. Conclusions were formulated concerning strain inhomogeneity and strain-hardening intensity with respect to the correlation between strain and hardness. It was also concluded, that nonuniformity of hardening rate in a bulk can lead to local variations in flow stress and eventually, to occurrence of the metal flow related defects, which was illustrated with a case study of cold heading of self-tapping screw of AISI 304Cu stainless steel, with large head diameter to shank diameter ratio. In order to validate the obtained results, the same method was used for analysis of hardness development in steel 19MnB4.

FEM-Simulation of the electrode temperature distribution and crater formation. Part I: Breakdown of an electrical discharge

2004 ◽  
Vol 120 ◽  
pp. 429-437
Author(s):  
F. Soldera ◽  
A. Lasagni ◽  
F. Mücklich
Keyword(s):  
Metal Forming ◽  
Electrical Discharge ◽  
Cathode Surface ◽  
Fem Simulation ◽  
Crater Formation ◽  
Impact Zone ◽  
Electrode Temperature ◽  
Material Loss ◽  
Cylindrical Samples ◽  
Good Agreement

An electrical discharge causes an energy input into the electrode, which melts and evaporates the metal forming a crater on the cathode surface. The larger part of material loss is produced by the ejection of molten particles from the molten pool. From calorimetric results, the amount of energy delivered to the cathode was estimated. Based on FEM, a model was developed to simulate the local temperature increase in the vicinity of the plasma impact zone. Considering phase transitions, it was possible to define a molten and an evaporated region, whose dimensions were compared with the dimensions of experimental craters. Single sparks were produced on cylindrical samples (Pt, Ir, Ru, Al, Au, Ag, Cu, W, Ni, Sn and Pb) in air and nitrogen with pressures ranging from 1 to 9 bar and electrode gaps of 1 and 2 mm. The volumes of experimental craters lay between the volumes of the simulated regions for 5 and 7 bar. For 1 and 3 bar, the volumes of the evaporated regions were overestimated. The shape of the simulated regions showed a very good agreement with the real craters. The relative volumes of the molten regions showed a very good agreement with the relative volumes of eroded material in the different metals.

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