Finite Element Calculation of the Polymer Stamp Material Redistribution under Restrictions on Fatigue Life

2022 ◽  
Vol 1049 ◽  
pp. 248-254
Author(s):  
Ivan Andrianov
Keyword(s):  
Finite Element ◽  
Fatigue Strength ◽  
Stress State ◽  
Geometric Model ◽  
Optimization Methods ◽  
Optimization Method ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Calculation Results ◽  
Rejection Coefficient

The numerical method of stamp topological optimization taking into account fatigue strength is presented in the work. It is proposed to take into account the restrictions on the stress state in accordance with the curve of the dependence of the maximum stresses on the number of loading cycles in the ESO topological optimization method. An approach to the selection of the evolutionary coefficient with a step-by-step increase in the rejection coefficient is proposed when constructing an iterative scheme for the rejection of elements by the method of topological optimization. The calculation of the stamp optimal topology with a decrease in volume due to the removal and redistribution of material was carried out in the study. The new geometric model of the optimal topology stamp is based on the predicted distribution of elements with a minimum stress level. The verification calculation of the stress state of the stamp of optimal topology with an assessment of fatigue strength was carried out in the work. The numerical calculation was carried out using the finite element method in the Ansys software package. The minimized stamp volume decreased by 35% according to the calculation results. The results of the study can be further applied in the development of topological optimization methods and in the design of stamping tools of optimal topology.

scholarly journals Development of the Sequential Voids Creation Approach in Axisymmetric Forming Dies

2021 ◽  
Vol 2096 (1) ◽  
pp. 012116
Author(s):  
I K Andrianov
Keyword(s):  
Elastic Modulus ◽  
Fatigue Strength ◽  
Stress State ◽  
Metal Forming ◽  
State Level ◽  
Optimization Methods ◽  
Optimization Method ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Strength Curve

Abstract The study deals with the problem of topological optimization of forming dies with a limitation on fatigue strength. As a model of a stamp, a typical geometric configuration of stamps for the manufacture of parts of the " cup " type is considered. The algorithm for finding the optimal topology is proposed to be built separately in the internal areas under the stamp flanges and under the bottom of the "cup" of forming. Mathematical regularities are presented, according to which elements that fall into the area of predicted removal have a very small elastic modulus, which is widely used in topological optimization methods, then the stress state level is analyzed according to the fatigue strength curve. In the area of the flanges, there is a "build-up" of the mass according to the quadratic law with a variation in the depth of removal of the material. In the area of the bottom of the " cup " of forming, a step-by-step addition of rod elements is proposed until the level of the stress state meets the specified restrictions. Thus, this study is a modification of the topological optimization method. The novelty of the research lies in the construction of a new geometric scheme for determining the area of stored and deleted elements. The results of the study can be further developed in the development of methods for effective redistribution of material, as well as significantly reduce the material costs for the production of metal forming dies.

scholarly journals Topological Optimization of a Complex Shape Forming Stamp

2021 ◽  
Vol 2096 (1) ◽  
pp. 012115
Author(s):  
I K Andrianov
Keyword(s):  
Mathematical Modeling ◽  
Fatigue Strength ◽  
Stress State ◽  
Software Package ◽  
Complex Shape ◽  
Scientific Research ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Ansys Software ◽  
Cold Stamping

Abstract The scientific research is devoted to the mathematical modeling of the optimal topology of stamps with a complex forming surface. Topological optimization is based on the SIMP method by creating a field of pseudo-densities and minimizing the pliability of the structure under the influence of load. When setting the problem, it is proposed to take into account the fatigue strength of polymers, taking into account the restrictions on the stress state. According to the results of the calculation in the ANSYS software package, an optimal redistribution of the stamp material and a reduction in volume due to the removal of elements that have little effect on the rigidity of the structure is obtained. The results of the study can be further applied in the field of hot and cold stamping by creating stamping tools of minimal volume.

Reverse Modeling and Topological Optimization for Lightweight Design of Automobile Wheel Hubs with Hollow Ribs

2019 ◽  
Vol 17 (09) ◽  
pp. 1950064
Author(s):  
P. F. Xu ◽  
S. Y. Duan ◽  
F. Wang
Keyword(s):  
Finite Element ◽  
Lightweight Design ◽  
Element Model ◽  
Optimization Method ◽  
Modeling Technique ◽  
Topological Optimization ◽  
Time Interval ◽  
Braking Performance ◽  
Existing Structures ◽  
Physical Conditions

Lightweight of wheel hubs is the linchpin for reducing the unsprung mass and improving the vehicle dynamic and braking performance of vehicles, thus, sustaining stability and comfortability. Current experience-based lightweight designs of wheel hubs have been argued to render uneven distribution of materials. This work develops a novel method to combine the reverse modeling technique with the topological optimization method to derive lightweight wheel hubs based on the principles of mechanics. A reverse modeling technique is first adopted to scan and reproduce the prototype 3D geometry of the wheel hub with solid ribs. The finite element method (FEM) is then applied to perform stress analysis to identify the maximum stress and its location of wheel hub under variable potential physical conditions. The finite element model is then divided into optimization region and nonoptimized region: the former is the interior portion of spoke and the latter is the outer surface of the spoke. A topology optimization is then conducted to remove the optimization region which is interior material of the spokes. The hollow wheel hub is then reconstructed with constant wall thickness about 5[Formula: see text]mm via a reverse modeling technique. The results show that the reconstructed model can reduce the mass of 12.7% compared to the pre-optimized model. The present method of this paper can guarantee the optimal distribution of wheel hub material based on mechanics principle. It can be implemented automatically to shorten the time interval for optimal lightweight designs. It is especially preferable for many existing structures and components as it maintains the structural appearance of optimization object.

scholarly journals New Design Procedure of Transtibial ProsthesisBed Stump Using Topological Optimization Method

Symmetry ◽  
2020 ◽  
Vol 12 (11) ◽  
pp. 1837 ◽  
Author(s):  
Martin Sotola ◽  
David Stareczek ◽  
David Rybansky ◽  
Jiri Prokop ◽  
Pavel Marsalek
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Design Procedure ◽  
Optimization Method ◽  
Topological Optimization ◽  
Element Analysis ◽  
Current Application ◽  
Transtibial Prosthesis ◽  
Walking Biomechanics ◽  
The Impact

This paper presents a new design procedure for production of a transtibial prosthesis bed stump by three-dimensional (3D) printing with topological optimization. The suggested procedure combines the medical perspective with finite element analysis and facilitates regaining the symmetry in patients with transtibial prosthesis, which leads to life improvement. The particular focus of the study is the weight reduction of the lower part of the bed stump, while taking into account its stiffness and load-bearing capacity. The first part of the work deals with the analysis of the subject geometry of the bed stump, which is usually oversized in terms of the weight and stiffness that are necessary for the current application. In the second part, an analysis of walking biomechanics with a focus on the impact and rebound phases is presented. Based on the obtained information, a spatial model of the lower part of the bed stump is proposed in the third phase, in which the finite element method is described. In the fourth part, the topological optimization method is used for reducing the structure weight. In the last part, the results of the designed model are analyzed. Finally, the recommendations for the settings of the method are presented. The work is based on the practical industry requirements, and the obtained results will be reflected in the design of new types of transtibial prosthesis.

Application of Topological Optimization on Aluminum Alloy Automobile Wheel Designing

2012 ◽  
Vol 562-564 ◽  
pp. 705-708
Author(s):  
Zhi Jun Zhang ◽  
Hong Lei Jia ◽  
Ji Yu Sun ◽  
Ming Ming Wang
Keyword(s):  
Topology Optimization ◽  
Lightweight Design ◽  
Optimization Method ◽  
Variable Density ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Element Analysis ◽  
Material Interpolation ◽  
Strength And Stiffness

Topology optimization method based on variable density and the minimum compliance objective function was used on designing the wheel spokes. SIMP material interpolation model was established to compensate these deficiencies of variable density method. Considering manufacturing process and stress distribution, five bolt wheels was chose to topology optimization. The percentage of material removal of the optimal topology 40% was reasonable. Finite element analysis was used to test the strength and stiffness of the structure of the wheel, the result meets the requirements after wheel topology optimization, and reduces the quality of wheels to 7.76kg, achieve the goals of lightweight design.

Topological Optimization of Coronary Stents

2015 ◽  
Author(s):  
Shijia Zhao ◽  
Linxia Gu
Keyword(s):  
Radial Stress ◽  
Optimization Method ◽  
Homogenization Method ◽  
Topology Design ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Patient Specific ◽  
Stent Design ◽  
Restenosis Rate ◽  
Radial Stiffness

The structural topological optimization method is an effective way to find the optimal topology of stents, which could be tailored for targeted stent performance, such as scaffolding ability, foreshortening, potential restenosis rate, etc. The radial stiffness is one of the major characteristics about stent performance. In this work, the homogenization method was utilized for the optimization of stent designs with the objective of maximizing the scaffolding ability of stent, i.e. its radial stiffness. A few design choices were presented by changing the number and distribution of strut connectors while keeping the void volume as 80%. The obtained optimal topology illustrated that the material distribution was mainly determined by the radial stress applied onto the stent. The optimal topology design in this work paves the way for the following dimension design, which can be targeted to the customized stent design for patient-specific lesions.

scholarly journals The Action Result of the Concentrated Load on the Briquettes which Obtained from the Technogenous Material

2017 ◽  
Vol 2 (2) ◽  
pp. 97
Author(s):  
Yu.N. Loginov ◽  
N.А. Babailov ◽  
D.N. Pervukhina
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Stress State ◽  
The Finite Element Method ◽  
Concentrated Load ◽  
Tensile Stresses ◽  
Calculation Results ◽  
Element Method

<p class="TTPAbstract">In this study, the calculation results of the briquette stress state by the Finite element method are presented. The fields of compressive and tensile stresses in briquette are determined. The conditions affecting the process of the briquette destruction are considered.</p>

scholarly journals ANALYSIS OF THE STRESSED STATE OF THE AXLE OF A WHEEL PAIR OF A PASSENGER CAR

2021 ◽  
pp. 62-72
Author(s):  
Igor Martynov ◽  
Alena Trufanova ◽  
Vadim Petukhov ◽  
Vadim Shovkun
Keyword(s):  
Finite Element ◽  
Stress State ◽  
Cross Sections ◽  
Geometric Model ◽  
Three Dimensional ◽  
Work Conditions ◽  
Passenger Cars ◽  
Wheel Pair ◽  
Passenger Car ◽  
Finite Element Grid

The paper considers the results of calculations of the axle of the wheel pair of apassenger car for strength and durability from fatigue. The loads acting on the axle of a passengercar during movement at the maximum permissible speed are determined.To solve the problems of studying the stress state of the axle of the passenger car at the firststage, a three-dimensional geometric model of the axis RU1 was developed. The most unfavorableload combination was taken into account in the calculation. The horizontal load was up to 10 kN.The load was applied to the axle necks, respectively, in the vertical and horizontal directions.The calculated model of the car axle RU1 is developed, on the basis of which the finiteelementmodel is created and the stress state of the wheel pair under the action of the main types ofload is investigated. The size of the finite element grid was chosen using a graphoanalytical methodand refined to a size of 2 mm. This feature of the finite element grid allowed to calculate thestresses in the calculated cross sections with greater accuracy and to determine the nature of thestress distribution.It is established that the maximum stresses arising in the axle of the passenger car under the most unfavorable work conditions that are concentrated in the filler in the zone oftransition from the neck to the pre-axle part.The axle was calculated for fatigue. Fatigue tests are usually performed at a uniaxial stressstate, so it is necessary to convert the multiaxial stress state to one scalar value to determine thenumber of cycles to failure at a given voltage amplitude. The load can occur with a constantamplitude.The number of load cycles that the car axle can withstand under operating loads isdetermined. According to the results of the research, restrictions on the service life of the axles ofwheel pairs of passenger cars are proposed.

The Topological Optimization of the Fixing Plank for the Hydraulic Motor

2015 ◽  
Vol 757 ◽  
pp. 105-108
Author(s):  
Chen Jiang Cao ◽  
You Jun Wang ◽  
Qiu Juan Lv
Keyword(s):  
Finite Element ◽  
Optimization Method ◽  
Topological Optimization ◽  
Stress And Strain ◽  
Hydraulic Motor ◽  
Before And After ◽  
Bearing Structure

The stress and strain of the fixing plank of the hydraulic motor were analyzed by the finite element analyze software Ansysworkbench. Then the topological optimization method was used to optimize the fixing plank so as to find out the best bearing structure. In the end,fixing plank was further improved and designed for a second time in Solidworks. According to the comparison of the finite element analyze results before and after the topological optimization, the weight of the fixing plank reduced by 30% while the stress and strain nearly keep the same.

Research on Optimization method of power flow of cylindrical shell stiffener based on BESO

2021 ◽  
Vol 263 (6) ◽  
pp. 30-41
Author(s):  
Xiaoyan Teng ◽  
Zhihua Yan ◽  
Xudong Jiang ◽  
Qiang Li
Keyword(s):  
Finite Element ◽  
Cylindrical Shell ◽  
Power Flow ◽  
Element Model ◽  
Optimization Method ◽  
Topological Optimization ◽  
Flow Sensitivity ◽  
Flow Response ◽  
Beam Coupling ◽  
Iterative Optimization Algorithm

In order to establish a method for topological optimization of the power flow response of a cylindrical shell stiffener structure based on BESO, this paper will combine the BESO topology optimization theoretical and the power flow response theory , and take the overall minimization of the power flow of the cylindrical shell stiffener structure as the optimization goal. Then an iterative optimization algorithm for the layout of the stiffener structure on the cylindrical shell surface can be established. The plate-beam coupling structure is used to simulate the cylindrical shell stiffener structure, a finite element model of the cylindrical shell stiffened is established and solved to obtain the power flow sensitivity of the finite element. This is used as an iterative criterion for the layout of the stiffener on the surface of the cylindrical shell structure optimize. Through the analysis of numerical examples, it is obtained that the optimization of the rib layout can better reduce the overall power flow response of the structure, which also verifies the feasibility of the optimization method.

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