FEM Simulation of Copper Busbar Pressing on the Continuous Extrusion Line "CONFORM"

2018 ◽  
Vol 284 ◽  
pp. 547-551
Author(s):  
Georgy V. Shimov ◽  
Aleksandr Bogatov ◽  
D. Kovin
Keyword(s):  
Steady State ◽  
Deformation Zone ◽  
Metal Flow ◽  
Fem Simulation ◽  
Continuous Extrusion ◽  
3D Package ◽  
Deform 3D

Simulation using the DEFORM-3D package of the steady-state pressing mode of a copper busbar on the continuous extrusion line "Conform" was carried out. The nature of the metal flow in the deformation zone was studied. An analysis of the velocities of the metal flow in the prechamber was performed. It was shown that in the channel of the wheel there is pressing out, which negatively affects the quality of the finished busbars and can lead to such defects as "lamination".

scholarly journals Evolution of the Microstructure of the Copper Alloy (DIN-ECu-57) in the Deformation Zone in the Process of Pressing Conform

2018 ◽  
Vol 918 ◽  
pp. 145-151
Author(s):  
Alexander V. Zinoviev ◽  
Alexander N. Koshmin ◽  
Alexander Y. Chasnikov
Keyword(s):  
Mechanical Properties ◽  
Cross Sections ◽  
Metal Forming ◽  
Deformation Zone ◽  
Copper Alloy ◽  
Copper Alloys ◽  
Metal Flow ◽  
Longitudinal Direction ◽  
Microstructure And Mechanical Properties ◽  
Continuous Extrusion

The process of continuous extrusion Conform, relating to modern energy-efficient metalworking technologies, is now widespread in the production of hollow and solid long-cut profiles of various cross-sections made of aluminum and copper alloys. However, in questions relating to the metal flow pattern and the formation of microstructure and mechanical properties, directly at the deformation zone, it has not studied sufficiently [1]. The work aimed at studying the nature of the metal flow and the transformation of the microstructure and mechanical properties of the copper alloy GOST-M1 (DIN-ECu-57) in the deformation zone during the pressing of round (Ø 8, 24, 30 mm) and flat (10 × 30, 10 × 60, 10 × 80, 10 × 100 mm) profiles. It was performed on the basis of New Metallurgical Technologies Ltd. and the department of metal forming of the NUST MISiS. In the pressing process, the templates of these profiles were selected, further samples for experiment were made and the study of the nature of the alloy flow in the longitudinal direction were carried out (continuous casting - deformation center - finished profile).

scholarly journals Finite element simulation of tool wear in machining of nickel-chromiumbased superalloy

2021 ◽  
Author(s):  
Andrea Abeni ◽  
Cristian Cappellini ◽  
Aldo Attanasio
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Tool Life ◽  
Experimental Approach ◽  
Fem Simulation ◽  
Tool Geometry ◽  
Element Analysis ◽  
Element Simulation ◽  
Deform 3D

The phenomenon of tool wear strongly affects the efficiency of machining and the quality of machined products. The experimental approach to investigate tool wear requires several time consuming tests. Finite Element Methods (FEM) can be utilized to predict tool wear and tool life as function of process parameters and tool geometry. The commercial software for Finite Element Analysis (FEA) are limited by the impossibility to update the geometry of the worn tool. This research utilizes a self-released subroutine in order to modify the tool geometry in DEFORM 3D simulations by considering the volume reduction of the tool. The model was validated with experimental data obtained by drilling tests on Inconel 718 using conventional metal working fluids (MWF). The correct profile of the simulated worn tool was individuated by comparing the prediction of the simulation with the real tool geometry. The FEM simulation allowed to predict how torque changes during the tool life. In a predictive maintenance perspective, the model can be implemented to optimize the tools replacement.

FEM Simulation of Weld Quality of AA6063 Aluminium Alloy Profiles during Continuous Extrusion Process with Double Feedstocks

2013 ◽  
Vol 641-642 ◽  
pp. 427-431 ◽  
Author(s):  
Ying Zhao ◽  
Bao Yun Song ◽  
Jiu Yang Pei ◽  
Chun Bo Jia ◽  
Bing Li ◽  
...  
Keyword(s):  
Aluminium Alloy ◽  
Fem Simulation ◽  
Extrusion Process ◽  
Weld Quality ◽  
Extrusion Welding ◽  
Extruded Product ◽  
Welding Line ◽  
Product Surface ◽  
Continuous Extrusion

In this study, a FE simulation model of the continuous extrusion process with double feedstocks is established. It is aimed to investigate the weld quality of AA6063 aluminium alloy profiles. The results show that with the height of preformed die increasing, the pressure-to-effective stress ratio (K) increases greatly and the welds can be improved. The maximum value of K reaches to 5.5. By observation the microstructure of the welding zone, the extrusion welding line does not extend to the product surface. No defects appeared on the surface of the extruded product. It is proved that the AA6063 product with good welding quality can be obtained by continuous extrusion with double feedstocks. These also provide the theoretical basis for expanding the application of the continuous extrusion process with double feedstocks.

Simulation of vibration piercing of pipe blank at press

2020 ◽  
Vol 76 (11) ◽  
pp. 1128-1138
Author(s):  
S. R. Rakhmanov
Keyword(s):  
High Frequency ◽  
Deformation Zone ◽  
Pipe Blank ◽  
Equipment Operation ◽  
Metal Deformation ◽  
Technological Tool ◽  
High Frequency Vibrations ◽  
Pipe Blanks ◽  
Wave Phenomena

In some cases, the processes of piercing or expanding pipe blanks involve the use of high-frequency active vibrations. However, due to insufficient knowledge, these processes are not widely used in the practice of seamless pipes production. In particular, the problems of increasing the efficiency of the processes of piercing or expanding a pipe blank at a piercing press using high-frequency vibrations are being solved without proper research and, as a rule, by experiments. The elaboration of modern technological processes for the production of seamless pipes using high-frequency vibrations is directly related to the choice of rational modes of metal deformation and the prediction resistance indicators of technological tools and the reliability of equipment operation. The creation of a mathematical model of the process of vibrating piercing (expansion) of an axisymmetric pipe blank at a piercing press of a pipe press facility is an actual task. A calculation scheme for the process of piercing a pipe plank has been elaborated. A dependence was obtained characterizing the speed of front of plastic deformation propagation on the speed of penetration of a vibrated axisymmetric mandrel into the pipe workpiece being pierced. The dynamic characteristics of the occurrence of wave phenomena in the metal being pierced under the influence of a vibrated tool have been determined, which significantly complements the previously known ideas about the stress-strain state of the metal in the deformation zone. The deformation fields in the zones of the disturbed region of the deformation zone were established, taking into account the high-frequency vibrations of the technological tool. It has been established that the choice of rational parameters (amplitude-frequency characteristics) of the vibration piercing process of a pipe blank results in significant increase in the efficiency of the process, the durability of the technological tool and the quality of the pierced blanks.

scholarly journals Effect of Tool Geometry Parameters on the Formability of a Camera Cover in the Deep Drawing Process

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3993
Author(s):  
Thanh Trung Do ◽  
Pham Son Minh ◽  
Nhan Le
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Metal Flow ◽  
Sheet Thickness ◽  
Side Wall ◽  
Tool Geometry ◽  
Drawing Process ◽  
Nose Radius ◽  
Deep Drawing Process

The formability of the drawn part in the deep drawing process depends not only on the material properties, but also on the equipment used, metal flow control and tool parameters. The most common defects can be the thickening, stretching and splitting. However, the optimization of tools including the die and punch parameters leads to a reduction of the defects and improves the quality of the products. In this paper, the formability of the camera cover by aluminum alloy A1050 in the deep drawing process was examined relating to the tool geometry parameters based on numerical and experimental analyses. The results showed that the thickness was the smallest and the stress was the highest at one of the bottom corners where the biaxial stretching was the predominant mode of deformation. The problems of the thickening at the flange area, the stretching at the side wall and the splitting at the bottom corners could be prevented when the tool parameters were optimized that related to the thickness and stress. It was clear that the optimal thickness distribution of the camera cover was obtained by the design of tools with the best values—with the die edge radius 10 times, the pocket radius on the bottom of the die 5 times, and the punch nose radius 2.5 times the sheet thickness. Additionally, the quality of the camera cover was improved with a maximum thinning of 25% experimentally, and it was within the suggested maximum allowable thickness reduction of 45% for various industrial applications after optimizing the tool geometry parameters in the deep drawing process.

scholarly journals A Head Formulation for the Steady-State Analysis of Water Distribution Systems Using an Explicit and Exact Expression of the Colebrook–White Equation

Water ◽  
2021 ◽  
Vol 13 (9) ◽  
pp. 1163
Author(s):  
Mengning Qiu ◽  
Avi Ostfeld
Keyword(s):  
Steady State ◽  
Distribution System ◽  
Distribution Systems ◽  
Water Distribution ◽  
Solution Method ◽  
Water Distribution System ◽  
Academic Research ◽  
Exact Expression ◽  
Contamination Source

Steady-state demand-driven water distribution system (WDS) solution is the bedrock for much research conducted in the field related to WDSs. WDSs are modeled using the Darcy–Weisbach equation with the Swamee–Jain equation. However, the Swamee–Jain equation approximates the Colebrook–White equation, errors of which are within 1% for ϵ/D∈[10−6,10−2] and Re∈[5000,108]. A formulation is presented for the solution of WDSs using the Colebrook–White equation. The correctness and efficacy of the head formulation have been demonstrated by applying it to six WDSs with the number of pipes ranges from 454 to 157,044 and the number of nodes ranges from 443 to 150,630. The addition of a physically and fundamentally more accurate WDS solution method can improve the quality of the results achieved in both academic research and industrial application, such as contamination source identification, water hammer analysis, WDS network calibration, sensor placement, and least-cost design and operation of WDSs.

scholarly journals The Effect of Process Parameters in Helical Rolling of Balls on the Quality of Products and the Forming Process

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2125 ◽  
Author(s):  
Janusz Tomczak ◽  
Zbigniew Pater ◽  
Tomasz Bulzak
Keyword(s):  
Metal Flow ◽  
Experimental Tests ◽  
Rolling Process ◽  
Helical Rolling ◽  
Forming Process ◽  
University Of Technology ◽  
Quality Of Products ◽  
Skew Rolling

This paper presents selected numerical and experimental results of a skew rolling process for producing balls using helical tools. The study investigates the effect of the billet’s initial temperature on the quality of produced balls and the rolling process itself. In addition, the effect of billet diameter on the quality of produced balls is investigated. Experimental tests were performed using a helical rolling mill available at the Lublin University of Technology. The experiments consisted of rolling 40 mm diameter balls with the use of two helical tools. To determine optimal rolling parameters ensuring the highest quality of produced balls, numerical modelling was performed using the finite element method in the Forge software. The numerical analysis involved the determination of metal flow kinematics, temperature and damage criterion distributions, as well as the measurement of variations in the force parameters. The results demonstrate that the highest quality balls are produced from billet preheated to approximately 1000 °C.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

scholarly journals Difficulty in Assessing Quality of Life Outcomes in a Fluctuating Disease: A Hypothesis Based on Gastroparesis

2009 ◽  
Vol 2009 ◽  
pp. 1-3 ◽  
Author(s):  
Vic Velanovich
Keyword(s):  
Quality Of Life ◽  
Steady State ◽  
Disease Process ◽  
Preliminary Finding ◽  
Median Number ◽  
Underlying Assumption ◽  
Clinical Encounters ◽  
Idiopathic Gastroparesis ◽  
Clinic Visits

An underlying assumption of quality of life outcome research is that after some intervention a “steady-state” of quality of life is reached which can be identified as an endpoint, and, hence, the “outcome.” However, in some disease processes, no so such steady-state is reached. The hypothesis presented is that a disease process with a waxing and waning course will make it difficult to determine a quality of life endpoint. After clinical observation, a pilot study of patients with either diabetic or idiopathic gastroparesis with gastric neurostimulation their records were reviewed to identify the number of clinic visits, the number of clinic visits in which the patients were asymptomatic, much improved, improved, no change, worse, or much worse. These changes were defined as “transitions.” A “transition ratio” was calculated by dividing the number of transitions by the number of clinic visits. Preliminary results showed that of 32 patients, the median number of clinic encounters was 8 (1–35), and the median number of transitions 4 (0–22). The average transition ration was . In the case of gastroparesis, over half of all clinical encounters were associated with a transition. The implication of the hypothesis and preliminary finding suggests a difficulty to identify when the symptomatic endpoint was reached. Other methods to assess the effects of treatment in such a disease process are required to fully understand the effects of treatment on quality of life.

Mathematical simulation of seamless pipes extrusion and rational calibration of die

2021 ◽  
Vol 77 (1) ◽  
pp. 70-79
Author(s):  
S. R. Rakhmanov
Keyword(s):  
Mathematical Simulation ◽  
Deformation Zone ◽  
Metal Flow ◽  
Flow Speed ◽  
Zone Length ◽  
Technology Application ◽  
Extrusion Press ◽  
Length Increase ◽  
Die Profile ◽  
Zone Parameters

Technology of seamless pipes production by extrusion enables to deform pipe workpieces made of low-plastic materials. However, low durability of the working instrument restricts the area of the technology application. The purpose of the work was to specify optimal parameters of technological processes of pipes extrusion. Minimization of energy and force parameters of the deformation zone and an increase of once-only metal deformation were accepted as criteria. They will enable to increase the presses productivity, increase durability of working instrument and accuracy of pipes geometric dimensions. A mathematical model of deformation zone and stressed state of pipe workpiece were elaborated. Influence of the die generatrix calibration and deformation zone parameters on the character of energy and force parameters change revealed. Dependence of energy and force parameters on the die calibration and geometric parameters of deformation zone for the press 50 MH was established. The results of mathematical simulation of pipes extrusion showed that along the whole deformation zone length, increase of metal flow speed results in an increase of tangential and normal stresses on the forming mandrel and calibrated die. The task of parametric optimization of die profile (calibration) was accomplished in interpretation of base variation Euler’s task for a determined functional of pipes extrusion. It was established that while the extrusion speed is increasing, the energy and force parameters of the deformation zone are getting pronounced dynamic character. At that, by optimization of die calibration, an increase of the extrusion press 50MH working instruments durability was reached, as follows: dies – by two times, mandrels – by 4 times, container bushes – by 40% and press-washers – by 2 times.

Sign in / Sign up

Export Citation Format

Share Document