Constrained Groove Pressing(CGP):Die Design,Material Processing and Mechanical Characterization

Constrained groove pressing(CGP)is a severe plastic deformation(SPD)technique used as a strengthening method for sheet metal.In the current work,an optimal/cost-saving design for CGP dies was attained using the stress analysis tool in SolidWorks Simulation Xpress wizard.This study examined low-cost and widely industrially applied aluminium materials,i.e.,pure 1050 Al and 5052 Al alloy.Each material was subjected to three passes of the CGP process using a 150 tons capacity press.For both materials,inter-pass annealing treatment was undertaken before the third pass.The effect of the number of CGP passes on the microstructure and tensile properties was studied after each pass.For CGPed pure 1050 Al with respect to the as-received material,the ultimate tensile strength(UTS),yield strength(YS)and YS/UTS ratio increased with an increasing number of CGP passes until the second pass,while elongation decreased with the number of passes.For CGPed 5052 Al alloy,the UTS and YS increased after the first pass and then decreased after the second pass.Variations in the elongation and YS/UTS ratio of 5052 Al alloy after the CGP process were insignificant.After inter-pass annealing and applying the third CGP pass,the strength of pure 1050 Al decreased,and that of 5052 Al alloy increased,which was attributed to the influence of composition on their structures.The strength-ductility balance decreased with an increasing number of CGP passes in both materials.

Die design and process optimization of die cast V6 engine blocks

The use of aluminum, particularly for engine blocks, has grown considerably in the past ten years, and continues to rise in the automotive industry. In order to enhance the quality and engineering functionality of die cast engine blocks, die design and processes have to be optimized. In this study, a computer simulation software, MAGMAsoft, as an advanced tool for optimizing die design and casting process, was employed to virtually visualize cavity filling and patterns of a V6 engine block. The original die design and process was simulated first to establish a baseline. A reality check was used to verify the predicted results. Then, the die modification with a different runner system was made by using a CAD software, Unigraphics (UG). The simulation on combinations of the modified die design and revised process was performed to examine the effect of die modification and process change on flow filling of V6 engine blocks. The simulated prediction indicates that the enhancement of cavity filling due to the die and process modification minimizes the occurrence of defects during casting, and consequently improves the quality of blocks. The results of mechanical testing show a significant increase in fatigue strengths, and a moderately improvement on tensile properties for the blocks die cast with the new die design and process in comparison with those produced by the original ones.

USING LOGIC COMPONENTS FOR CONCEPTUAL DIE DESIGN

Logic components are used to support the conceptual design Taking the stamping die structure as the research object,several logic components are defined for the conceptual die construction design A new method logic assembly modeling is presented to satisfy the characteristic of the top down die design process Representing shapes and spatial relations in logic can provide a natural,intuitive method of developing complete computer systems for reasoning about die construction design at the conceptual stage This method can reflect the designer's thought clearly and provide the designer with a test bed for generating alternatives and performing reasoning work at the conceptual die design stage

NUMERICAL DESIGN OF DIE LAND FOR SHAPE EXTRUSION

In the extrusion of shapes with flat faced die,the proper design of die land is of critical importance in avoiding the generations of geometry defects.A methodology for the design of die land,which consists of a simulation adjustment iteration,is proposed.The metal flow in extrusion is simulated by the three dimensional finite element method and the die land is adjusted according to the simulation result.Both the formulae for adjustment of the die land and the criterion for the judgment of proper die land are suggested.The extrusion of an L section shape is chosen as the computational example and the result is compared with the industrial design.

Heat Treat ment of Die and Mould Oriented Concurrent Design

Many disadvantages exist in the traditional die design method which belongs to serial pattern. It is well known that heat treatment is highly important to the dies. A new idea of concurrent design for heat treatment process of die and mould was developed in order to overcome the existent shortcomings of heat treatment process. Heat treatment CAD/CAE was integrated with concurrent circumstance and the relevant model was built. These investigations can remarkably improve efficiency, reduce cost and ensure quality of R and D for products.

An Integrated Die Casting Design System

Die casting process is one of the prime options for m anufacturing precisely dimensioned, sharply defined metal parts. The design of d ie casting dies comprises several stages and entails a large amount of time. Tra ditionally, the different stages of the die design were not integrated but exist as separate entities. Moreover, recurring modifications or even redesigns are r equired due to the complexity in achieving an accurate initial die design. As a result, die design is usually time-consuming and costly with respect to resourc es. The die casting industry will greatly benefit if proper application software are developed that integrates the different die design stages and allows editin g of die design as and when needed. Hence it is imperative to create an integrat ed die design system that shortens the die design time. This paper presents a research that establishes a prototype of an integrated die design system. It is developed using the commercial SolidWorks CAD system and n amed DiWorks. The aim of building the system on a commercial CAD system is to ut ilise the resources and features of the CAD system to speed up the die design pr ocess. DiWorks consists of six distinct modules: Project Manager, Cavity Insert Builder, Gating System Constructor, Die Base Designer, Ejector System Constructo r and Standard Components Library. Through these six modules, the die designer c an create a complete die casting die beginning from a product part model. It is a user-friendly system that allows both experienced and novice die designers to easily accomplish the task of die design. The practical goal of this research is twofold: to develop a system that integra tes the die design process and at the same time facilitates the editing of d ie design during or after the course of the design process. The research approac h includes (i) parametric design, (ii) feature-based design (iii) system modeli ng and implementation. Parametric design deals with variable dimensions as contr ol parameters, and it is an efficient tool for creating models based on paramete rs. Parametric design not only increases the design efficiency, but also makes t he updates and modifications of existing designs easier and faster, since these can be achieved by changing the parameters of the parametric model. Feature-bas ed design is used to design a product with features that are functionally define d by attributes and are geometrically represented by a set of parameters. The re sults of this research will aid the automation of the die design process, thus i mproving the efficiency and quality of, and reducing the cost of die design.

THEORETICAL ANALYSES ON DESIGN OF SHEAR EXTRUSION DIE

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Stress Analysis and Optimum Design of PDC Die for Offshore Drilling Engineering

The maximum internal tangential stress is a critical parameter for the design of the PDC （polycrystalline diamond compact） die that has been widely applied to offshore oil drilling. A new simple equation for the calculation of the stress is developed, and verified by the test data from Kingdream Corp. of China, the largest bit Company in China. An opti- mum method for the design of the PDC die is presented and demonstrated in detail, and software for the design and FEM analysis of the die is developed on the basis of the method. This software has been used in oil industry in recent years.

Analytical design of dies for the extrusion of sheets and annular parison

Based on the method of representative values and the flow pattern, that is, the position of the isobars parallel to the die orifice （PIPDO）, the design of dies for the sheet and annular parisons was improved in the present paper. Since this pattern includes the effects of the sloped manifold and the equations for designing the circular manifold are independent of operating conditions and the material, the distribution system of a die gives better uniformity of flow. In the previous study by Winter a defect was found, that is, the calculated position of the path of the island area lagged behind actual position. This defect was eliminated, and the modified equation was obtained. Another flow pattern, in which the pressure loss on all flow path is equal （PLFPE）, was introduced. The equivalency of the above two flow patterns was proved theoretically in this paper.

FEM simulation of aluminum extrusion process in porthole die with pockets

In order to investigate the effects of pockets in the porthole die on the metal flow,temperature at the die bearing exit and the extrusion load were contrasted with the traditional die design without the pockets in the lower die.Two different multi-hole porthole dies with and without pockets in lower die were designed.And the extrusion process was simulated based on the commercial software DEFORM-3D.The simulation results show that the pockets could be used to effectively adjust the metal flow and especially benefit to the metal flow under the legs.In addition,the maximum temperature at the die bearing and the peak extrusion load decrease,which indicates the possibility of increasing the extrusion speed and productivity.

Design, Fabrication and Experimentation of a Deep Drawing Machine

This paper presents the work implemented in designing, fabricating and operating a model of a cheap hydraulic DDM （deep drawing machine）, which is currently utilized in the manufacturing processes lab in the IED （Industrial Engineering Department） at An-Najah National University. The machine is used to conduct different experiments related to the deep drawing process. This work was implemented in three stages： the first was the design stage, in which all design calculations of the DDM elements were completed based on the specifications of the product （cup） to be drawn; the second was the construction stage, in which the DDM elements were fabricated and assembled at the engineering workshops of the university; the last was the operating and experimentation stage, in which the DDM was tested by conducting different experiments. The experience gained from designing and constructing such a mechanical lab equipment was found to be successful in terms of obtaining practical results that agree with those available in literature, cost-effective relative to the cost of a similar purchased equipment, as well as enhancing students＇ abilities in understanding the deep drawing process in particular and machine elements design concepts in general.

V6 Pro/design在级进模设计中的应用

介绍了V6Pro/design的展开、排样、模具系统、特征孔系统、轮廓特征单元设计、拆图与细部设计等各部分功能,指出了V6Pro/design的优点与不足。

UBET analysis of process of extruding aluminum alloy ribbed thin-wall pipes through a porthole die

Using the upper bound element technique (UBET), a numerical model was proposed for analyzing the metal deformation behavior in the extrusion process of ribbed thin wall pipes through a porthole die. Optimization parameters were contained in the numerical model and determined through minimizing the total work of metal deformation. Taking the extrusion process of thin wall pipe with one rib as an example, the calculated results using the proposed model are as follows: the extrusion pressure p is linearly related to the extrusion ratio R by p = a+bR 0.683 , where a = 14.13, b = 0.911. When the length of the billet remaining in container is shorter than a quarter of the container diameter, the plastic region extends over the whole of the remained billet and the extrusion process reaches the state of funnel deformation. There exists an optimum depth of welding chamber in respect of the extrusion pressure, and to the calculated example the optimum depth is about 10% of the circumscribed diameter of portholes. To obtain more equitable metal flow in welding chamber, it is required to make the dividing planes in container to be consistent with corresponding welding planes in the chamber ( θ max i = θ′ max i ) through choosing different entering area for each of the portholes.

Research of PDC Bit Compact Die With FEM and Optimum Method

In mould design, it is necessary for a designer to ensure that the cylinder has enough intensity in both the prestressed and synthesis states. An individual layer cylindrical mould cannot withstand a very high pressure needed in polycrystalline diamond composite (PDC) production. So, multi-layer prepressure combination assemble moulds are often used. The analysis conducted here is to study the interaction of cylindrical layers and to explain how to obtain enough load capability with the lowest requirement of material performance. The ratio of the pressure cylinder radius of synthetic diamond is 3.27, which is close to the optimal value and can be used as structure size in a design for PDC bit compact die. There is a linear relationship between the internal and external pressures under a special tangent stress on the inner wall of the pressure cylinder. So, when two of the three parameters (the internal pressure, external pressure, and the requirement value of the tangent stress on the inner wall of the pressure cylinder) are given, the third can be obtained. The sleeve acts as a bridge?between the pressure cylinder and the steel belts. The optimum model developed in this paper can be used in PDC bit compact die design and other similar prestressed cold extrusion die design.

汽车车灯支架压铸工艺CAE分析及模具设计

分析了汽车车灯支架的结构特点,进行了压铸工艺设计,并应用ProCAST软件对该铝合金压铸件的充型过程、压铸模具热平衡和温度场进行了数值模拟分析,预测缺陷产生的位置及原因,根据预测结果对模具结构进行了优化。实际生产表明,采用优化后的模具设计方案提升了铸件质量。

基于“PBL+云平台”的《冲压工艺与模具设计》课程改革探索与实践

模具制造技术专业的核心课程《冲压工艺与模具设计》正受到授课内容布置、教学实施、成绩评估等方面的限制,随着互联网技术与教育的融合,以平台规划、学情分析及教学评价为突破口,基于云平台建设了《冲压工艺与模具设计》在线课程,并以PBL模式实施教学,实现了资源与知识点匹配衔接,形成了既能合理运用资源实施多种方法授课,又会创作资源的创新型课程教学团队,助推人才培养质量。

基于“互联网+教育”的模具设计与制造专业课程教学改革的探索

针对模具设计与制造专业课程理论逻辑性强、过于抽象的教学难点,以互联网为基础,利用网络教学平台,通过线上、线下混合的教学方法及教学反思,不断推动“互联网+教育”在模具设计与制造专业课程中的应用,促进专业课程教学改革,以提高学生学习的自主性,激发学生学习的热情,提高教学质量。

基于真空压铸技术的机壳压铸模设计

通过对机壳压铸件的结构工艺分析,介绍了真空压铸技术下模具的浇注系统、成型零件、侧向分型与抽芯机构、推出机构、溢流与排气系统、温度控制系统等机构的设计要点,相比普通压铸的模具,能有效减低压铸原材料的损耗,提升压铸件质量,为类似模具的设计提供一定的参考借鉴。

虚拟现实技术赋能的《模具设计与制造》实证研究

通过实证分析探讨了虚拟现实技术在高职《模具设计与制造》课程教学中的应用及其对教学效果的影响。研究表明,虚拟现实技术的引入能够提高学生的学习兴趣,增强互动性和实践操作的真实感,有效提升学生的学习效率和技能掌握水平。研究也指出了虚拟现实技术在教学实践中存在的一些挑战和限制,如成本投入、技术配套和教师培训等问题。

游戏化教学策略在模具设计课程中的实施与评估

探讨了游戏化教学策略在模具设计课程中的实施并进行了效果评估,通过综合运用理论分析和实证研究,考察了游戏化教学的核心元素及其如何融入模具设计教学中。通过引入游戏元素,分析其对提升学生学习动机、认知能力、情感态度和合作交流的影响,并分析和评估该策略的有效性,发现游戏化教学提高了学生的课堂参与度和学习成效,学生对游戏元素的接受度高,反馈积极,显示游戏化教学在增强学习体验方面的有效性。此外,教学实践的成果分析表明,游戏化教学有助于学生更好地掌握模具设计的专业知识和技能,为高职模具设计课程的教学改革提供了新的视角和方法,展示了游戏化教学在技术教育领域的潜力和价值。