Use of Taguchi Method to Study a Robust Design for H-Sectioned Porous Beams during Rolling

2007 ◽  
Vol 561-565 ◽  
pp. 1845-1848
Author(s):  
Dyi Cheng Chen ◽  
Cheng Fu Chen
Keyword(s):  
Taguchi Method ◽  
Three Dimensional ◽  
Rolling Process ◽  
Processing Parameters ◽  
Process Conditions ◽  
Plastic Deformation Behavior ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Roll Gap ◽  
Stress And Strain Distribution

Commercial DEFORMTM three-dimensional finite element (FE) code is employed to examine the plastic deformation behavior of porous beams at the roll gap during the H-sectioned rolling process. The simulations assume that the rolls are fully rigid and that the change in temperature induced in the beams during rolling can be ignored. The simulations systematically examine the respective effects of the arc radius of the H-section flange region of the upper and lower rolls, the friction factor between the beam and the rolls, the density of the porous beams and the radii of the upper and lower rolls on the filling ratio at the roll gap, the thickness reduction of the rolled beam in the flange region, and the effective stress and strain distribution induced in the rolled product. The Taguchi method is then employed to optimize the processing parameters for the H-sectioned rolling of porous beams. Overall, the simulation results confirm the effectiveness of the Taguchi design methodology as a means of optimizing the H-sectioned rolling process conditions.

Numerical Analysis of Friction Distribution in the Rod Rolling Process

2010 ◽  
Vol 34-35 ◽  
pp. 893-897
Author(s):  
Li Cheng Yang ◽  
Shang Le Qing ◽  
Xuan Huang ◽  
Yi Ping Luo
Keyword(s):  
Friction Force ◽  
Three Dimensional ◽  
Simulation Method ◽  
Rolling Process ◽  
Processing Parameters ◽  
Finite Element Models ◽  
New Approach ◽  
Dimensional Finite Element ◽  
Rod Rolling ◽  
Three Dimensional Finite Element

The three dimensional finite element models of rod have been built on the basis of thermo-mechanical coupled elastic-plastic FEM in order that the rolling process of No.5 pass is simulated accurately. The distributed rule of friction is calculated and discussed with variable initial rolling temperature, diameters of rollers, reduction in pass and rolling speeds. The results show that the fore sliding region, adhesive region and back sliding region are existent on the surface of rolling material. Furthermore, friction force is calculated by using numerical simulation method and it is a new approach in studying friction. The analysis of friction force is available for reference to optimize processing parameters in the rolling process.

Process Modeling in Laser Deposition of Multilayer SS410 Steel

2007 ◽  
Vol 129 (6) ◽  
pp. 1028-1034 ◽  
Author(s):  
Liang Wang ◽  
Sergio Felicelli
Keyword(s):  
Phase Transformation ◽  
Temperature Distribution ◽  
Three Dimensional ◽  
Element Model ◽  
Traverse Speed ◽  
Processing Parameters ◽  
Dimensional Finite Element ◽  
Net Shaping ◽  
Three Dimensional Finite Element ◽  
Continuous Cooling Transformation Diagram

A three-dimensional finite element model was developed to predict the temperature distribution and phase transformation in deposited stainless steel 410 (SS410) during the Laser Engineered Net Shaping (LENS™) rapid fabrication process. The development of the model was carried out using the SYSWELD software package. The model calculates the evolution of temperature in the part during the fabrication of a SS410 plate. The metallurgical transformations are taken into account using the temperature-dependent material properties and the continuous cooling transformation diagram. The ferritic and martensitic transformation as well as austenitization and tempering of martensite are considered. The influence of processing parameters such as laser power and traverse speed on the phase transformation and the consequent hardness are analyzed. The potential presence of porosity due to lack of fusion is also discussed. The results show that the temperature distribution, the microstructure, and hardness in the final part depend significantly on the processing parameters.

The Analysis of the Stress and Strain in Skew Rolling

2012 ◽  
Vol 538-541 ◽  
pp. 1650-1653 ◽  
Author(s):  
Hai Bo Yang ◽  
Li Jie Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Three Dimensional ◽  
Element Model ◽  
Rolling Process ◽  
Stress And Strain ◽  
Workpiece Material ◽  
Center Edge ◽  
Dimensional Finite Element ◽  
Helical Groove ◽  
Three Dimensional Finite Element ◽  
Skew Rolling

In this paper, three-dimensional finite-element model for the skew rolling (helical-groove rolling) process has been used to characterize the workpiece material stress,strain and deformation behavior. Particular attention has been paid to representative cross section and the center, edge and mid-radius points of the billet

Analysis of Polypropylene Deformation in a 135° ECAE Die: Experiments and Three-Dimensional Finite Element Simulations

2009 ◽  
Vol 424 ◽  
pp. 71-78 ◽  
Author(s):  
Ben Aour ◽  
Fahmi Zaïri ◽  
M. Naït-Abdelaziz ◽  
J.M. Gloaguen ◽  
J.M. Lefebvre
Keyword(s):  
Finite Element ◽  
Equal Channel Angular Extrusion ◽  
Deformation Behaviour ◽  
Three Dimensional ◽  
Processing Parameters ◽  
Fe Method ◽  
Saturation State ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Number Of Passes

Plastic deformation of polypropylene (PP) resulting from equal channel angular extrusion (ECAE) process was investigated in a 135° die. A phenomenological elastic-viscoplastic constitutive model was identified and coupled with the three-dimensional finite element (FE) method in order to predict the different processing parameters governing the deformation behaviour of PP during the extrusion. An optimal agreement between FE results and experimental data was obtained for a friction coefficient of 0.2. A detailed three-dimensional FE analysis of stress-strain field distribution was then carried out. The effects of both the number of extrusion passes and the processing routes were experimentally highlighted. The results show that the pressing force decreases with the increase of the number of extrusion passes and reaches its saturation state rapidly for routes A and C while, for routes BA and BC, it requires a high number of passes.

Numerical Investigation of Lubricated Deep Rolling Process in a Complex Roller Path

2014 ◽  
Vol 966-967 ◽  
pp. 406-424
Author(s):  
Joe J. Liou ◽  
Tahany I. El-Wardany
Keyword(s):  
Residual Stress ◽  
Three Dimensional ◽  
Element Model ◽  
Rolling Process ◽  
Deep Rolling ◽  
Strain Rate Effects ◽  
Near Surface ◽  
Roller Path ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

Deep rolling process is a mechanical surface treatment that provides several advantages, such as low friction on the interface between the tool and workpiece in the process, controlled profile of induced compressive residual stress to enhance the HCF and LCF strength, enhancement of the stability of the near-surface structure at high temperature, and improvement of surface finish after the process. This paper investigates the deep rolling process under lubricated condition for a complex deep rolling path. A three-dimensional finite element model incorporating the strain hardening and strain rate effects on the material responses is developed to sequentially simulate the continuous multi-axis roller motion in the process. This model can capture the horizontal and normal forces acting on the roller so that a time-varying apparent coefficient of friction can be obtained. In addition, due to the complex roller path, the model also predicts a complex residual stress distribution in the near-surface material.

Stress Analysis of Cross Wedge Rolling for Alloy Steel with Three-Dimensional Finite Element Simulation

2012 ◽  
Vol 529 ◽  
pp. 224-227
Author(s):  
Bin Li ◽  
Hong Wang
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Rolling Process ◽  
Stress Distributions ◽  
Cross Wedge Rolling ◽  
Workpiece Material ◽  
Dimensional Finite Element ◽  
The Cross ◽  
Three Dimensional Finite Element

This paper investigates a three-dimensional finite element model for the cross-wedge rolling process has been used to characterize the workpiece material stress and deformation behavior. Considering the characteristic of cross wedge rolling, the static implicit FEM program is selected. To simulate all forming stages in the cross wedge rolling process, dynamic adaptive remeshing technology was applied. Examples of numerical simulation for strain, stress distributions and rolling load components have been included. The stress distributions in the cross-section of the forming workpiece are analyzed to interpret fracture or rarefaction at the center of workpiece. The computer codes in finite element method can be used for a large variety of problems by simply changing the input data.

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