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 verification of roll forming and springback process under complex contact conditions

The application of advanced high strength steel （AHSS） has an important significance in the development of the lightweight of automobile, but the parts made of AHSS usually have defects, such as fracture and large amount of springback, etc. In this paper, a model of multi-pass roll form- ing and springback process of AHSS is established with finite element software ABAQUS. Then a roll forming experiment is performed, and simulation and experimental results have been compared and analyzed. The model is established under complex contact conditions, including self-contact condi- tion. The results shows that during the process of sheet bending, large Mises stresses appear at ben- ding corners. The smaller the bending radius is, the larger the Mises stress and strain are. Thick- ness of sheet metal changes exceeds a certain limit, the differently if the bending radius is different. When the bending radius change tendency of the sheet thickness turns from increase to decrease.

Study on Contact Algorithm of Dynamic Explicit FEM for Sheet Forming Simulation

Based on existing algorithms, a newly developed contact search algorithm is proposed. The new algorithm consists of global search, local searching, local tracking and penetration calculation processes. It requires no iteration steps. It can deal with not only general tool surfaces with vertical walls, but also tool surfaces meshed with elements having very poor aspect ratios. It is demonstrated that the FE code employing this new contact search algorithm becomes more reliable, efficient and accurate for sheet metal forming simulation than conventional ones.

基于FEM和RSM的深穴圆柱滚子优化设计

为消除圆柱滚子端部的应力集中现象,提高滚动轴承的疲劳寿命,对圆柱滚子内修形-深穴结构的形状控制参数(深穴开口度k、深穴长度l、深穴锥角α)进行了分析,建立了滚子接触有限元(FEM)模型。基于响应曲面法(RSM),建立了以滚子端部与中间接触应力差最小为优化目标,以k,l和α为设计变量的优化数学模型,并对响应面模型进行了求解,得到一组最优解,通过对比分析表明深穴滚子可以有效地降低滚子端部的应力集中现象,优化后深穴滚子应力分布更为均匀,避免了因局部应力过大而过早发生疲劳失效;采用FEM与RSM相结合的优化方法操作简单、效率高,可将其应用于其他机械零部件的优化设计。

基于FEM的足尺落地式浅圆钢筒仓静态贮料作用分析

准确计算贮料对仓壁的作用,是大直径浅圆钢筒仓安全设计的前提.为此,采用有限单元法(FEM)对足尺落地式浅圆钢筒仓的静态贮料作用进行了数值模拟分析,包括小麦、铁矿石散粒、石英砂和水泥散料,其本构关系服从Drucker-Prager屈服非关联流动准则.采用3-D模型同时模拟了贮料和筒仓,建立考虑变形的面-面接触对,以更好地反映贮料对仓壁的静态作用.将FEM模拟值与国内外筒仓规范的计算结果进行了对比分析,并讨论了贮料力学参数的影响,表明FEM可作为一种准确、可靠的钢筒仓静态贮料作用计算工具.

基于FDM/FEM耦合的铸造热应力分析

使用华铸CAE铸造模拟软件模拟铸造过程的温度场,通过自主开发的温度转换模块,将华铸CAE计算的温度场结果转换为有限元温度载荷,并加载到ANSYS的有限元模型中,进行铸造热应力分析。使用ANSYS中的接触单元处理铸件与铸型之间力的相互作用,对典型应力框试件进行了热应力分析,并与自由收缩模型的计算结果进行了对比。结果表明,采用接触单元法的计算结果更为准确。

共轭鼓形齿面接触分析的FEM与BEM的对比研究

共轭鼓形齿轮传动接触问题是一有待深入研究的课题，在原有研究成果的基础上，对共轭鼓形齿轮传动接触问题进行了有限元与边界元方法的对比研究，并通过一实例计算得到了有关重要结论．

NUMERICAL SIMULATION OF TWO-POINT CONTACT BETWEEN WHEEL AND RAIL

The elastic-plastic contact problem with rolling friction of wheel-rail is solved using the FE parametric quadratic programming method. Thus, the complex elastic-plastic contact problem can be calculated with high accuracy and efficiency, while the Hertz＇s hypothesis and the elastic semi-space assumption are avoided. Based on the ‘one-point＇ contact calculation of wheel-rail, the computational model of ‘two-point＇ contact are established and calculated when the wheel flange is close to the rail. In the case of ‘two-point＇ contact, the changing laws of wheelrail contact are introduced and contact forces in various load cases are carefully analyzed. The main reason of wheel flange wear and rail side wear is found. Lubrication computational model of the wheel flange is constructed. Comparing with the result without lubrication, the contact force between wheel flange and rail decreases, which is beneficial for reducing the wear of wheel-rail.

Frictional contact algorithm study on the numerical simulation of large deformations in deep soft rock tunnels

There exist three types of nonlinear problems in large deformation processes of deep softrock engineering, i.e., nonlin- earity caused by material, geometrical and contact boundary. In this paper, the numerical method to tackle the nonlinear eontact and large deformation problem in A Software on Large Deformation Analysis for Soft Rock Engineering at Great Depth was presented. In the software, based on Lagrange multiplier method and Coulomb friction law, kinematic constraints on contact boundaries were introduced in functional function, and the finite element equations was established for two incremental large deformation analyses models, polar decomposition model and additive decomposition model. For every incremental loading step, by searching for the contact points in the potential contact interfaces （the excavation boundaries）, the Lagrange multipliers, i.e., contact forces are cal- culated iteratively by Gauss-Seidel method, and justified through satisfy the inequalities of static constraint on contact boundaries. With the software, large deformation and frictional contact of a transport roadway were analyzed numerically by the two models. The numerical examples demonstrated the efficiency of the method used in the software.

Nonlinear Dynamics Seismic Response of Container Crane Based on Contact Friction Theory

To evaluate the dynamic behavior of a container crane under seismic loads accurately,the contact state between the wheels and the rails or the ground that significantly affect the seismic response of the structure must be considered elaborately.This paper has proposed a modeling method based on the theory of contact and friction for simulating the nonlinear seismic response of large and flexible structure of a jumbo movable container crane,including the contact problem regarding the wheels attached to the bottom of its legs and the rails on which they ride.These models are used to perform extensive dynamic time-history analysis in order to find out their nonlinear dynamic behavior under various excitation modes.It is found that the presented numerical modeling method simulates the nonlinear seismic response of a container crane quite well.Notably,it can verify and expand our understanding of the seismic behaviors by evaluating response performance for the large seaport cranes.

RIGID-PLASTIC/RIGID-VISCOPLASTIC FEM BASED ON LINEAR PROGRAMMING—THEORETICAL MODELING AND APPLICATION FOR AXISYMMETRICAL PROBLEMS

Compared with the traditional rigid plastic/rigid viscoplastic(RP/RVP) FEM(based on iteration solution),RP/RVP FEM based on linear programming (LP) has some remarkable advantages,such as it's free of convergence problem and its convenience in contact,rigid zone,and friction force treatment.The numerical model of RP/RVP FEM based on LP for axisymmetrical metal forming simulation is studied,and some related key factors and its treatment methods in formulation of constraint condition are proposed.Some solution examples are provided to validate its accuracy and efficiency.

FEM-SPH耦合算法模拟铝液粒化的动态过程

针对传统基于网格方法不能有效模拟大变形问题的现状，本文引入SPH（Smoothed Particle Hydrodynamic）方法模拟液态钢渣（文中简称液渣）与粒化轮的碰撞过程．因液渣物性参数尚不完善，故以铝液代替并使用SPH方法建模，粒化轮则用FEM（Finite Element Method）建模，并通过接触算法实现FEM．SPH的耦合，研究了粒化轮转速、铝液的流速等因素对碰撞过程铝液液滴体积大小的影响．模拟结果表明：当SPH粒子承载质量为2．04×10-4ks时，粒化轮转速达到900rad／min；粒化前铝液流速为1m／s时粒化效果较好且体积多分布在1330～1930mm3；碰撞后粒子运动速度多集中在5～25m／s．

Finite Element Analysis of Elastic-Plastic Contact Mechanic Considering the Effect of Contact Geometry and Material Properties

Each surface of roughness has different shape of asperity which is modeled with various shapes of analytical models. In this paper, the differences among various models of shape of asperity investigate using the Finite Element Method (FEM) and various analytical models. The contact stresses in rough surfaces are calculated analytically using various asperity shape models. Finite element analysis is also carried out assuming three types of material properties namely, the linear, the elastic-perfect plastic and the elastic-nonlinear hardening. The analytical results are compared with the results obtained by the finite element method. The results illustrate for using a deterministic approach which the numerical models are suitable. In hertz model, the result of force is very big in interface of causing deformation plastic, while Model Zhao has almost same result with FEM nonlinear property model. It is observed that the results obtained from Zhao’s model are generally in a better agreement with the results obtained from various finite element models especially in elastic-plastic and plastic zones, hence it may be concluded that Zhao’s model can be used for analyzing the rough surfaces in contact mechanics.

Generation Principle of Helix Tooth Profile in Hypocycloid Pinw heel Transmission and Its Contact Characteristics

The transmission characteristics of gear drive can be improved with the use of novel tooth profiles.A theoretical study on tooth profile of the hypocycloid pinwheel transmission and contact analysis of gear pair based on finite element method(FEM) are carried out,respectively.The line contact between mated tooth surfaces becomes point contact according to a plus movement.Through loaded tooth contact analysis(LTCA),the contact stress and load distributions for the proposed hypocycloid pinwheel transmission and the traditional one are discussed.The analysis results show that the developed tooth surfaces have anticipatory point contact characteristics under loads and contact fatigue dangerous area locates around the ultimate contact position.

Dynamic Contact Problem for Slide Hinge

Contact analysis can be either static or dynamic. In static contact analysis, the position on the contact surface is constant. In dynamic contact analysis, the position on the contact surface changes at every time step. In static contact analysis, the computing results (stress, strain, etc.) of contact states have been verified through the Hertz contact problem in literature. On the other hand, there has been insufficient research into dynamic contact analysis. The contact algorithm is insufficiently constructed in finite element model (FEM) discretization. The gap between two objects cannot be calculated accurately. A contact method is demanded for artificial parameters. Inappropriate setting of artificial parameters causes artificial numerical oscillations on the contact surface between objects. To develop a high-reliability satellite, we started the development of FEM contact-friction modeling techniques in this study. A dynamic contact method was realized by using the appropriate parameters required in the contact analysis. We verified the reproducibility of the physical behavior of the contact friction via numerical simulation techniques by using a computational model of the hinge joints.

Multi-body Contact Problem of Loose-fitted Tyre of Rotary Kiln

According to the character and the condition for shell deformation and force balance, we have set up the mathematical models of the contact angle and the contact pressure distribution between the tyre and the shell, studied The features of a multi-body contact model between the roller and the tyre, and developed the build-up procedure of the contact finite element model between the roller and the tyre. The stress distribution rule of the roller and the tyre is obtained as follows. The contact center is the center of the contact stress circle, and the contact stress is also reduced gradually from the contact center to the contact boundary. The equivalent stress of the tyre varies 5 times per circle, thus making the trye fracture easily.

五强溪水电厂底孔密封性能仿真模拟研究

针对水电站闸门水封存在密封性能在运行过程中裂化、密封性能预测困难、水封更换时螺栓预紧量的确定缺乏理论依据等问题,提出基于多元线性回归的螺栓预紧量补偿模型。结合工程实例,通过Ogden公式建立方头P型水封橡胶超弹性本构模型,建立复杂工况下水封密封结构非线性有限元计算模型。基于Ansys计算了4种影响因素下的水封接触应力,分析了多种影响因素与水封密封性能之间的独立影响和综合影响规律,在有限元分析的基础上,基于多元线性回归建立了接触应力计算公式,构建了螺栓预紧量补偿模型,实现了水封密封性能反演和螺栓预紧量补偿计算。结果表明,基于螺栓预紧量补偿模型得到的接触应力与预期值的平均相对误差为7.6%,最大相对误差为16.9%,模型能够实现在水封安装工况改变时对螺栓预紧量进行修正,从而得到预期水封密封性能,为实际工程中水封结构的设计、安装提供了可靠依据。

水平振动式滚磨光整加工残余应力离散元有限元耦合仿真与实验研究

为探究水平振动式滚磨光整加工对零件表面残余应力的影响,提出一种适用于动态零件的离散元有限元(DEM-FEM)耦合仿真方法。分析了振动周期内颗粒运动状态以及颗粒间平均接触力的变化,构建了颗粒与零件间的随机接触模型,开展了不同振动参数下的残余应力仿真,并进行了实验验证。研究结果表明:随着振动强度的增大,容器内颗粒运动更加剧烈,颗粒与零件间有效法向接触力发生概率及均值增大,导致零件表面残余压应力呈增大趋势。残余应力仿真值与实验值对振动参数的响应趋势一致,误差在3.6%~11.3%之间。

大温差地区CRTSⅠ型板式无砟轨道层间动态受力特征

大温差地区单元式轨道板受日照影响会产生较大温度梯度,导致轨道板翘曲变形,诱发轨面不平顺,增加高速列车轮轨冲击响应,加速轨道结构损伤。针对这一问题,采用有限元方法,首先建立考虑层间关系的无砟轨道静力分析模型,对大温度梯度下轨道板翘曲变形及轨面周期性不平顺进行分析;然后,建立车辆-轨道系统动力学模型,模拟分析温度梯度作用下无砟轨道层间动态受力特征,研究高速行车条件下无砟轨道真实服役状态。结果表明:温度梯度作用下,轨道板呈椭球形变形趋势,正温度梯度时轨道板中部向上鼓起、4角支承,负温度梯度时轨道板4角翘起、板中支承;温度梯度会导致轨道板与CA砂浆间产生不同程度离缝,板下接触面积减小,高速行车时层间接触面积逐渐增加,但离缝不会完全闭合;负温度梯度对轨道结构振动和砂浆层受力影响较小,正温度梯度影响较大,温度梯度为90℃·m^(-1)时,轨道板振动加速度增大10倍左右,轨道板与CA砂浆层间压力最大值增加6.6倍,板角处CA砂浆应力较无温度梯度下钢轨正下方CA砂浆应力增加5.4倍,正温度梯度下轨道板侧边及4角位置处CA砂浆受力加剧效应显著,是导致该区域CA砂浆出现结构性破坏的主要原因。

基于COMSOL的钢结构连接板接触面积的检测

借助COMSOL有限元仿真软件建模,通过改变接触面的接触半径,将接触面积率作为设计参数,并在瞬时激励下激发应力波,使结构表面的压电片产生电压信号。通过分析电压信号得到应力波在不同接触面积率下的透射系数R,采用最小二乘法拟合得到接触面积率与等效刚度的关系,并结合应力波通过接触面的透射系数的解析解,测定真实接触面积。将此方法应用于钢结构柱节点连接板接触面积检测中,接触面积率检测的绝对误差在0.06%~4.75%,证明了此方法的有效性。