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.

Mathematical model for abrasive suspension jet cutting based on orthogonal test design

This paper describes the application of orthogonal test design coupled with non-linear regression analysis to optimize abrasive suspension jet （AS J） cutting process and construct its cutting model. Orthogonal test design is applied to cutting stainless steel. Through range analysis on experiment results, the optimal process conditions for the cutting depth and the kerr ratio of the bottom width to the top width can be determined. In addition, the analysis of ranges and variances are all employed to identify various factors： traverse rate, working pressure, nozzle diameter, standoff distance which denote the importance order of the cutting parameters affecting cutting depth and the kerf ratio of the bottom width to the top width. ~rthermore, non-linear regression analysis is used to establish the mathematical models of the cutting parameters based on the cutting depth and the kerr ratio. Finally, the verification experiments of cutting parameters＇ effect on cutting performance, which show that optimized cutting parameters and cutting model can significantly improve the prediction of the cutting ability and quality of ASJ.

Meta-analysis of commercial Pt/C measurements for oxygen reduction reactions via data mining

The rotating disk electrode technique is commonly used for screening and characterizing the performance of electrocatalysts for the oxygen reduction reaction(ORR).However,a reliable performance comparison of different electrocatalysts from different labs remains a challenge because of the inconsistency in the measurement of commercial Pt/C.Commercial Pt/C has been adopted extensively as a reference for evaluating the ORR performance of a new electrocatalyst.However,the reported ORR performances of commercial Pt/C from different labs could be significantly different because of multiple factors.Herein,we conducted a meta‐analysis of the ORR performance of commercial Pt/C via data mining of the literature.This revealed the optimal testing conditions for the most repeatable ORR performance,with commercial Pt/C in both acid and alkaline electrolytes;the optimal Pt loading was 20μg/cm^(2) on a 4 mm glassy carbon working electrode.The value of 0.84±0.03 V was suggested as the“Golden reference”of the commercial Pt/C(with Pt 20 wt%)ORR half‐wave potential for the performance evaluation of other ORR catalysts in both acid and alkaline electrolytes.The conclusion obtained through the meta‐analysis was confirmed by experiments.This study provides general guidance for a reliable measurement of the ORR performance of commercial Pt/C as a reference.

Calculation Method of Wave Forces on Large Round-Ended Caisson Foundation

This paper presents an analytical formula for estimating the longitudinal wave forces on a large roundended caisson foundation. The establishment of the formula is based on the superposition of the theoretical formula of wave forces on a large circular cylinder and the empirical formula of wave forces on a large rectangular cylinder. With the formula transformed into an inertial force form, a specific inertia coefficient with an exact expression is extracted from the formula. The numerical calculations of the wave forces on round-ended cylinders are carried out by the boundary-element method. The undetermined coefficients in the expression of the inertial coefficient are determined by the numerical results. It is obvious that the numerical values can be well expressed by the computation values from the established formula. By a model experiment carried out in laboratory wave flume, the correctness of the analytical formula is further verified by the measured wave forces on a test model of a round-ended bridge caisson foundation. The comparison shows that the experimental forces can be approximately estimated by this simple calculation method.