FEM Simulation of Welding Quality in Porthole Die Extrusion

The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.

3D FEM Simulation of Milling Force in Corner Machining Process

To optimize milling force and machining accuracy quality in corner milling process, the changing law of milling force is revealed by Finite Element Method（FEM）. Based on DEFORM software a serial of 3D FEM models for corner milling process are devloped. Tool curved trajectory is achieved by establishing accurate relationship of tool location with milling time. Adaptive remeshing technique and iterative algorithm are adopted to ensure convergence of FEM model. Component force characteristics are revealed by analyzing FEM simulation results. It indicates that the milling force in Y direction becomes negative comparing with forces in X and Z direction. Magnitude of forces in three directions decreases with increase of spindle speed, while it increases with increase of milling feedrate. The simulation results for cutting force are in good agreement with those obtained from experiment. The FEM simulation model is first successfully established for corner milling process in this study, and the results provide a guide for optimizing cutting parameters in cutting process.

Three-Dimensional Rigid-Plastic FEM Simulation of Bulk Forming Processes with New Contact and Remeshing Techniques

Some techniques such as die surface description, contact judgement algorithm and remeshing are proposed to improve the robustness of the numerical solution. Based on these techniques, a three-dimensional rigid-plastic FEM code has been developed. Isothermal forging process of a cylindrical housing has been simulated. The simulation results show that the given techniques and the FEM code are reasonable and feasible for three-dimensional bulk forming processes.

FEM SIMULATION AND EXPERIMENTAL RESEARCH ON THE SHEET BLANKING

Both experiment and simulation are made on the AlMg4 . 5Mn0 .4 sheet blanking with 1 % , 10% and 20% relative clearance respectively. The cutting force curves and the cutting surface parameters which can be used to describe the quality of the blankings are measured. Simulation is accomplished by MARC Autoforge software package. Calculated cutting forces are always bigger than measured ones. All difference between experiment and simulation is not greater than 20% . It is feasible making virtual experiment on workstation to estimate the cutting force and to predict the quality of the workpiece for new material using certain blanking technical parameters.

3D FEM Simulation of Precision Forging Automobile Clutch Damping Spindle Sleeve

The precision forging process is simulated by commercial software Deform 3D using a rigid visco-plastic model to predict the status of metal flow and the distribution of equivalent plastic strain, providing guidance for making decision on the optimal choice of process parameters and mould structure. Trial forging was used to verify the effectiveness of FEM simulation results.

FEM SIMULATION FOR LASER FORMING PROCESSING

Laser forming involves heating sheet metal workpiece along a certain path with adefocused laser beam directed irradiate to the surface. During laser forming, a tran-sient temperature fields is caused by the irradiation and travelling of a laser beam.Consequently, thermal expansion and contraction take place, and allows the thermal-mechanical forming of complex shapes. This is a new manufacturing technique thatforming metal sheet only by thermal stress. Therefore, the analysis of temperaturefields and stress fields are very useful for studying the forming mechanism and con-trolling the accuracy of laser forming. The non--liner finite element solver, MARC, isemployed to solve the thermal--mechanical analysis. Using this model, the stress andstrain distribution of pure aluminum plate with different thickness are analyzed. Theinfluence of scanning speed on temperature fields and plastic strain of metal sheet un-der the condition of constant line energy are also presented. Numerical results agreewell with the experimental results.

Multiphysics FEM Simulation of Contour Induction Hardening Process on Aeronautical Gears

Induction heating has been widely used by the heat treatment industry mainly in the wind-power and automotive sectors,in particular for hardening purposes,in a broad range of applications,its main advantages being the high repeatability and easy automation of the process,both factors leading to improved manufacturing efficiency and reduced CO;emissions.Though,traditional furnace-based case hardening treatments still represent the choice of reference when performance requirements are particularly demanding,either for the critical operating conditions or safety-related issues.The processes of CIH（Contour Induction Hardening）,compared to the traditional carburizing processes,allows to reduce the deformations after heat treatment.The main purpose of these treatments,as well as increases the surface hardness of the piece,is to induce compressive stresses in the superficial layer,improving the fatigue behavior.A multiphysics magneto-thermal simulation can be developed in order to calculate the temperature distribution in the gear,setting the input parameters such as currents,frequencies and treatment times.

FEM NUMERICAL SIMULATION OF THE SOFT MEDIUM TUBE EXPANSION PROCESS

In this paper the soft medium tube expanding process of different loading case and tube sheet structure is simulated with FEM. The expanding patterns under different conditions are obtained. The correction of the Single-tube Model is verified, and cor- responding procedures are also proposed to correct the error.

Quantitative Prediction of Fracture Distribution of the Longmaxi Formation in the Dingshan Area, China using FEM Numerical Simulation

Fracture prediction is a technical issue in the field of petroleum exploration and production worldwide.Although there are many approaches to predict the distribution of cracks underground,these approaches have some limitations.To resolve these issues,we ascertained the relation between numerical simulations of tectonic stress and the predicted distribution of fractures from the perspective of geologic genesis,based on the characteristics of the shale reservoir in the Longmaxi Formation in Dingshan;the features of fracture development in this reservoir were considered.3 D finite element method(FEM)was applied in combination with rock mechanical parameters derived from the acoustic emissions.The paleotectonic stress field of the crack formation period was simulated for the Longmaxi Formation in the Dingshan area.The splitting factor in the study area was calculated based on the rock breaking criterion.The coefficient of fracture development was selected as the quantitative prediction classification criteria for the cracks.The results show that a higher coefficient of fracture development indicates a greater degree of fracture development.On the basis of the fracture development coefficient classification,a favorable area was identified for the development of fracture prediction in the study area.The prediction results indicate that the south of the Dingshan area and the DY3 well of the central region are favorable zones for fracture development.

Prediction of machining chatter in milling based on dynamic FEM simulations of chip formation

Chatter vibration is a major obstacle inachieveing increased machining performance. In thisresearch, a finite element model of chip formation in a 2Dmilling process is used to predict the occurrence of chattervibrations, and to investigate the effects of variousmachining parameters on this phenomenon. The dynamicproperties of the machine tool at the tool tip are obtainedbased on experimental modal analysis, and are used in themodel as the cutter dynamics. The model allows for thenatural development of vibration as the result of the chip-tool engagement, and accounts for various phenomena thatoccur at the chip-tool interface ultimately leading tostable or unstable cutting. The model was used todemonstrate the effects of the machining parameters, suchas the axial depth of cut, radial immersion, and feed rate,on the occurrence of chatter. Additionally, the phenomenonof jumping out of the cut region could be observed in thismodel and its effect on the chatter process is demonstrated.The numerical model is verified based on comparisons withexperimental results.

A STUDY OF EXPERT SYSTEM FOR SECTION EXTRUSION PROCESS BASED ON FINITE ELEMENT METHOD SIMULATION

The samples obtained by Finite Element Method (FEM) simulation for section extrusion process have been trained on BP Neural Networks. The mapping relationsbetween die's geometrical parameters and energetic parameters, such as stress and strain generated in the die are established. The extrusion process model and its expert system are also determined. The excellent expansibility this system possesses provides a new prospect for the future development of expert system for section extrusion dies.

Finite element simulations on the mechanical properties of MHS materials

Finite element simulations are carried out to examine the mechanical behavior of the metallic hollow sphere （MHS） material during their large plastic deformation and to estimate the energy absorbing capacity of these materials under uniaxial compression. A simplified model is proposed from experimental observations to describe the connection between the neighboring spheres, which greatly improves the computation efficiency. The effects of the governing physical and geometrical parameters are evaluated; whilst a special attention is paid to the plateau stress, which is directly related to the energy absorbing capacity. Finally, the empirical functions of the relative material density are proposed for the elastic modulus, yield strength and plateau stress for FCC packing arrangement of hollow spheres, showing a good agreement with the experimental results obtained in our previous study.

DEFORMATION ANALYSIS OF SHEET METAL SINGLE-POINT INCREMENTAL FORMING BY FINITE ELEMENT METHOD SIMULATION

Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.

SIMULATION OF HOT FORMING PROCESSION IN Mn18Cr18NSTEEL

In the hot forming of Mn18Cr18N steel, such problems as easy cracking, difficult controlling of forming paramenters often occur. In this paper,the variation rule of the plasticity of the steel, the starting mechanism of micro-crack and its generating characteristics were studied with the combination of thermodynamic simulation test, micro-simulation and FEM, the related data of microstructure change and hot forming parameters were produced. The hot forming process of 600MW generator retaining ring was analyzed as an example.

ELASTO-PLASTIC FEM ANALYSIS OF CYLINDER UPSETTING BETWEEN TWO FLAT PLATENS

A whole analysis model including forging and flat platens is built,which is used to analyse the process of upsetting a cylinder between flat platens.The influence of surface friction and transient temperature are comprehensively considered.By means of ANSYS software,the elasto plastic FEM analysis of the whole upsetting process is carried out.From the point of view of numerical calculation,the correctness of the centre region tension stress theory about upsetting a cylinder between flat platens is tested and verified.The concept of plasto nucleus is presented to explain the forming of double dumps.The efffect of temperature is inspected.The relation curves between the radial stress of the symmetry centre point and the relative pression ratio are given.

Adiabatic Shear Mechanisms for the Hard Cutting Process

The most important consequence of adiabatic shear phenomenon is formation of sawtooth chip. Lots of scholars focused on the formation mechanism of sawtooth, and the research often depended on experimental approach. For the present, the mechanism of sawtooth chip formation still remains some ambiguous aspects. This study develops a combined numerical and experimental approach to get deeper understanding of sawtooth chip formation mechanism for Polycrystalline Cubic Boron Nitride（PCBN） tools orthogonal cutting hard steel GCr15. By adopting the Johnson-Cook material constitutive equations, the FEM simulation model established in this research effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation, and the adiabatic shear phenomenon is simulated successfully. Both the formation mechanism and process of sawtooth are simulated. Also, the change features regarding the cutting force as well as its effects on temperature are studied. More specifically, the contact of sawtooth formation frequency with cutting force fluctuation frequency is established. The cutting force and effect of cutting temperature on mechanism of adiabatic shear are investigated. Furthermore, the effects of the cutting condition on sawtooth chip formation are researched. The researching results show that cutting feed has the most important effect on sawtooth chip formation compared with cutting depth and speed. This research contributes a better understanding of mechanism, feature of chip formation in hard turning process, and supplies theoretical basis for the optimization of hard cutting process parameters.

Fluid Pump Using a Bar-shaped Piezoelectric Transducer

There are two kinds of piezoelectric pumps:check valve pumps and valve-less pumps.Whether to use a check valve or not depends upon the application occasion.To achieve large backpressure for higher flow rates,the pump with check valve is desirable.However,adding check valves implies more complex structure and higher probability of valve blocking,etc.In order to solve the problem,effective driving and transport mechanics with compact construction and reliable service are being sought.In this paper,using the second-order longitudinal vibration mode of a bar-shaped piezoelectric vibrator for driving fluid,a piezoelectric pump is successfully made.The proposed piezoelectric pump consists of coaxial cylindrical shells and a bar-shaped piezoelectric vibrator,which has a disk part and a cone part.The lead zirconium titanate ceramic rings fixed in the vibrator are polarized along the thickness direction.When the second-order longitudinal vibration of the vibrator along its axis is excited,the disk part of the vibrator changes periodically the volume of the chamber and the cone part acts as a pin valve,driving the fluid from the inlet port to the outlet port.Finite elements analysis on the proposed pump model is carried out to verify its operation principle and design by the commercial FEM software ANSYS.Components of the piezoelectric pump were manufactured,assembled,and tested for flow rate and backpressure to validate the concepts of the proposed pump and confirm the simulation results of modal and harmonic analyses.The test results show that the performance of the proposed piezoelectric pump is about 910 mL/min in flow rate with a highest pressure level of 1.5 kPa under 400 V peak-to-peak voltage and 51.7 kHz operating frequency.It is confirmed that this bar-shaped piezoelectric transducer can be effectively applied in fluid transferring mechanism of pump through this research.

RESEARCH ON INFLUENCE OF TEMPERATURE ON A PRECISION FORGING PROCESS OF BLADE WITH A TENON

The blade precision forging process is a forming process with high temperature and large plastic deformation. Interaction of deformation and heat conduction leads to large uneven distribution of temperature. The unevenness of temperature distribution has a great effect on mechanical properties and the microstracture of materials. So it is necessary to consider the influence of temperature on the precision forging process of blades. Taking a blade with a tenon into consideration, a 3D mechanical model in precision forging is built up. The distribution laws of temperature field and the influence of the temperature on the equivalem stress in the process are obtained by using 3-D coupled thermo-mechanical FEM code developed by the authors Theresuits obtained illustrate that the influence of the temperature field on the blade forging process is considerable. The achievements of predicting microstructure and mechanical properties for forged blades is significant.

Numerical and Experimental Study of the Roughness Effects on Mechanical Properties of AISI316L by Nanoindentation

Surface roughness is a commonly used criterion for characterization of surface quality in a machining operation. In the study of micro-scale mechanical properties of machined surface and cutting tool using nanoindentation method, perfect surface finish on the specimen is often required for the reliable indentation result. However, the perfect surface finish is often difficult to obtain from the machining operation due to the dynamic behavior of the machining and the limitation of the cutting tool geometry. In the presented paper, the effect of surface roughness on the nanoindentation measurements is investigated by using finite element method. A 3D finite element model with seven levels of surface roughness is developed to simulate the load-displacement behavior in an indentation process with a Berkovich indenter. The material used in the simulation is AISI 316 L stainless steel, modeled as an elastic-plastic material. The mechanical properties were calculated by combining simulations with the Oliver-Pharr method. The hardness and reduced modulus from the simulation were found to decrease with an increase of roughness. The study showed that the scatter of the load-depth curves and the deviation of the hardness and the reduced modulus are significant affected by the variation of roughness. It was also found that the height of pile-up was little affected by the surface roughness from the simulation. The combined effect of indenter tip radius and surface roughness was also investigated. The study was complemented with experimental tests and the results from these tests support the results from the simulation.

Suppressing the mechanical quadrature error of a quartz double-H gyroscope through laser trimming

In this paper, we introduce a z-axis quartz gyroscope using a double-H tuning fork, which has a high sensitivity. However, it also causes a large mechanical quadrature error. The laser trimming method is used to suppress this error at quartz level. The trimming law is obtained through the finite element method （FEM）. A femtosecond laser processing system is used to trim the gold balancing masses on the beams, and experimental results are basically consistent with the simulated ones. The mechanical quadrature error is suppressed by 96%, from 26.3° s-1 to 1.1° s-1. Nonlinearity changes from 1.48% to 0.30%, angular random walk （ARW） is reduced from 2.19° h-1/2 to 1.42° h-1/2, and bias instability is improved by a factor of 7.7, from 197.6° h-1 to 25.4° h-1.