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.

OPTIMUMDESIGNOFSTREAMLINEDEXTRUSIONDIESBASEDONUPPERBOUNDMETHODANALYSIS

A more universal and flexible method of constructing the streamlined die surfaces is presented. The streamlined die surfaces are interpolated by the arbitrarily cross sectional shapes of the die entrance and exit. The boundaries of the die entrance and exit are represented by Ferguson curves with tension parameters. By adjusting the tension parameter, the cross sectional shapes of the die entrance and exit with line segments can be accurately constructed. The upper bound method is used to analyze the procedure of extrusion, the pseudo independent parameters in kinematically admissible velocity and die surface are computed by minimizing the extrusion load, so the optimum die surface is obtained. The effects of frictional condition, die length, area reduction and product shaped complexity are discussed in relation to the extrusion load.

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.

Die design for cold precision forging of bevel gear based on finite element method

The finite element analysis （FEA） software Ansys was employed to study the stress state of the dies of both plane and non-plane parting face structures with uniform interference and the die of plane parting face structure with non-uniform interference. Considering the symmetry of the die, a half gear tooth model of the two-ring assembled die with 2.5 GPa inner pressure was constructed. Four paths were defined to investigate the stress state at the bottom comer of the die where stress concentration was serious. FEA results show that the change of parting face from non-plane to plane can greatly reduce the stress at the teeth tips of the die so that the tip fracture is avoided. The interference structure of the die is the most important influencing factor for the stress concentration at the bottom comer. When non-uniform interference is adopted the first principal stress at the comer on the defined paths of the die is much lower than that with uniform interference. The bottom hole radius is another important influencing factor for the comer stress concentration. The first principal stress at the comer of the plane parting face die with non-uniform interference is reduced from 2.3 to 1.9 GPa when the hole radius increases from 12.5 to 16.0 mm. The optimization of the die structure increases the life of the die from 100 to 6 000 hits.

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.

RELIABILITY AND OPTIMIZATION DESIGN OF NEW ROLLER ORIENTATION CLUTCH

The mechanical reliability and optimization theory on the method ofreliability-optimization design for the new roller orientation clutch is provided. The result ofreliability-optimization design is compared with the result of the conventional design method.

3D Design and Analysis of Crushing Roller of High-pressure Grinding Roller

Crushing roller is one of the main parts of High-p re ssure Grinding Roller, which is a kind of high efficient ore crushing equipment. A kind of assembled roller, which is more convenient to renovate worn surface b y simply replacing segmented surface of the roller, was developed. The structura l models of assembled roller’s components were designed with SolidWorks softwar e based on feature modeling, these solid models of the roller were virtually ass embled. Through this work, not only was the assemble interference checked out so as to examine validity of the structure design, but also these solid models cou ld be recognized by COSMOS/Works software, through which the finite element an alysis can be done. Then the stress and displacement of the main shaft and sur face segment in two different working states were analyzed and detected quickly according to the analysis results with COSMOS/Works. In conclusion, the optimum clearance of 1.0～2.0 mm between concave-convex studded segments is determined to make the using life of assembled roller longer.

THEORETICAL ANALYSES ON DESIGN OF SHEAR EXTRUSION DIE

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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.

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.

Effects of runner design and pressurization on the microstructure of a high-pressure die cast Mg-3.0Nd-0.3Zn-0.6Zr alloy

To clarify the relationship between externally solidified crystals(ESCs)and other defects,e.g.,defect bands and pores,two dimensional(2D)and three dimensional(3D)characterization methods were adopted to analyze castings produced using a modified ingate system equipped with and without an ESC collector.The reduction of ESCs strongly reduced defect band width and shrinkage pore quantity.By reducing the quantity and size of ESCs,net-shrinkage pores were transformed into isolated island-shrinkage pores.We determined via statistical analysis that the mechanical properties of high pressure die castings were strongly related to the size and fraction of the ESCs rather than porosity volume.The reduction of ESCs also caused tensile transgranular fracture modes to transform into intergranular fracture modes.Additionally,casting pressurization strongly reduced pore morphology,volume,and size.

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.

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

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.

Profiled Cylindrical Roller Design in Consideration of Grinding Undercut Effect

In this paper, the effect of the grinding undercut of the raceways on the longitudinal pressure distribution of the profiled rollers, which are the most popular axial profile employed by the bearing manufacturers, was discussed. Based on the profiled roller geometrical equations and numerical calculation of three dimensional elastic contact problems of finite length, a new numerical method for calculating the crown drop evaluation considering the effect of grinding undercut was used. The analyses of two structure case, that roller length is greater or less than raceway width, were carried out and compared with each other. The Results show that the width of grinding undercut must be considered in determining the crown drop of rollers.

Development on Technique of Tube Reducing in Double 3-Roll Dies

Based on the experiments, a new technique of reducing tube with two linked 3-roll roller dies was developed. The external friction conditions, velocity and the non-uniform deformation of metal were distinctly improved, and the friction between metal and tool was decreased. Corrosion strip layers and photo-elastic coatings methods were adopted in the experiment for measuring residual stress, and the residual stresses in the drawn tube with 3-roll dies are reduced.

New trends in cold-chamber die casting machine design

Larger and larger proportions of aluminium castings,especially those produced by the die casting process,can be observed during recent years in the automotive industry,house-hold articles and others.In case of the automotive industry,apart from the traditional elements produced by the die pressure method such as engine blocks or crank shaft bedplates,aluminium is displacing steel from structural parts of cars('body in white').The current state and development directions of the structural solutions of cold-chamber die castings are analysed in this paper.These solutions drive the prospective development of these machines and die casting technology.The focus is mainly on essential functional systems such as:hydraulic drives of closing and locking units,as well as pressing in die machines of known companies present on the European market.

Optimal Design of Tapered Roller Bearings Based on Multi⁃Physics Objectives Using Evolutionary Algorithms

Rolling element bearing is the most common machine element in rotating machinery.An extended life is among the foremost imperative standards in the optimal design of rolling element bearings,which confide on the fatigue failure,wear,and thermal conditions of bearings.To fill the gap,in the current work,all three objectives of a tapered roller bearing have been innovatively considered respectively,which are the dynamic capacity,elasto-hydrodynamic lubrication(EHL)minimum film⁃thickness,and maximum bearing temperature.These objective function formulations are presented,associated design variables are identified,and constraints are discussed.To solve complex non⁃linear constrained optimization formulations,a best⁃practice design procedure was investigated using the Artificial Bee Colony(ABC)algorithms.A sensitivity analysis of several geometric design variables was conducted to observe the difference in all three objectives.An excellent enhancement was found in the bearing designs that have been optimized as compared with bearing standards and previously published works.The present study will definitely add to the present experience based design followed in bearing industries to save time and obtain assessment of bearing performance before manufacturing.To verify the improvement,an experimental investigation is worthwhile conducting.

Discussion on Lightning Protection Design of "Feilongzaitian" Roller Coaster of Fangte in Zigong

The lightning protection design of "Feilongzaitian" roller coaster of Fangte in Zigong was discussed, and the lightning protection measures of "Feilongzaitian" roller coaster were analyzed from the aspects of direct lightning protection, grounding and lightning electromagnetic impulse protection.

Fuzzy Reliability Design for the Interference Articulation of a Roller Shaft

With regard to function, the strengths for interference articulation of a roller shaft formed a series system. As the three strength reliabilities conditioned each other, there was a problem for the system reliability to apportion rationally. In fact, there was a transition from safety to deactivation. The state of structure was fuzziness which was in both safety and non-safety states. Therefore the reliability was a fuzzy event which considered the randomness for some design parameters and the fuzziness for the thresholds between generalized strength safety and deactivation. The mathematical model of fuzzy reliability design for the interference articulation of the roller shaft was presented. Eight design examples were calculated.