Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.

Visual Passive Ranging Method Based on Re-entrant Coaxial Optical Path and Experimental Verification

To overcome the shortcomings of the traditional passive ranging technology based on image, such as poor ranging accuracy, low reliability and complex system, a new visual passive ranging method based on re-entrant coaxial optical path is presented. The target image is obtained using double cameras with coaxial optical path. Since there is imaging optical path difference between the cameras, the images are different. In comparison of the image differences, the target range could be reversed. The principle of the ranging method and the ranging model are described. The relationship among parameters in the ranging process is analyzed quantitatively. Meanwhile,the system composition and technical realization scheme are also presented. Also, the principle of the method is verified by the equivalent experiment. The experimental results show that the design scheme is correct and feasible with good robustness. Generally, the ranging error is less than 10% with good convergence. The optical path is designed in a re-entrant mode to reduce the volume and weight of the system. Through the coaxial design,the visual passive range of the targets with any posture can be obtained in real time. The system can be widely used in electro-optical countermeasure and concealed photoelectric detection.

SCATTERING OF A GRAZING LONGITUDINAL WAVE PULSE BY A RIBBON-TYPE CRACK—EXPERIMENTAL VERIFICATION BY THE PHOTOELASTIC METHOD

By using the dynamic photoelastic method and our technique of fabricating an internal crack in solid , the scattered waves of incident grazing longitudinal ultrasonic wave pulse by a ribbon-type crack are ob-served and analyzed . In particular, the distribution of the intensity of the scattered head wave is measured quantitatively . The experimental results fairly agree with the theoretical ones given in ref. [ 1 ] .