Three Dimension Rigid-plastic Finite Element Simulation for Two-Roll Cross-wedge Rolling Process

Cross-wedge rolling (CWR) is a metal process of ro ta ry forming. To produce a part, one cylindrical billet should be placed between t wo counterrotating and wedge-shape dies, which move tangentially relative each other. The billet suffers plastic deformation (essentially, localized compressio n) during its rotation between the rotating dies. Compared to other numerical si mulation methods, the finite element method (FEM) has advantages in solving gene ral problems with complex shapes of the formed parts. In cross-wedge rolling, t here are four stages in the workpiece deformation process, namely knifing, guidi ng, stretching and sizing stage. It is time-consuming and expensive to design t he CWR process by trial and error method. The application of numerical simul ation for the CWR process will help engineers to efficiently improve the process development. Tselikov, Hayama, Jain and Kobayashi, and Higashimo applied the sl ip-line theory in study of CWR process analysis. Zb.pater studied CWR process i ncluding upsetting by upper-bound method. The above numerical simulation were b ased on the two-dimensional plain-strain assumption ignored the metal flow in workpiece axial direction. Therefore, the complex three-dimensional stress and deformation involved in CWR processes were not presented. Compared to other nume rical simulation methods, the finite element method (FEM) has advantages in solv ing general problems with complex shapes of the formed parts. As yet, a few 3-D finite element simulation studies on CWR process have been reported in literatu res. In this paper, the process of cross wedge rolling (CWR) has been simulated and analyzed by 3D rigid-plastic finite element method. Considering the charact eristic of CWR, the static implicit FEM program is selected. The models proposed in this study uses the commercial code DEFORM 3D to simulate the CWR process. T his is an implicit Lagrangian finite element code, which includes many new enhan cements functions. A new method of utilizing multiple processors using the MPI s tandard has been implemented. Automatic switching between the two different defo rmation solvers (Sparse Solver and Conjugate Gradient Solver) has also been impl emented in order to increase the speed of simulations. In this paper, all stages in CWR process are simulated to be able to closely understand and analyze the a ctual CWR process. For simulating all forming stages in CWR process, the dynam ic adaptive remeshing technology for tetrahedral solid elements was applied. T he stress distributions in cross section of forming workpiece are analyzed to in terpret fracture or rarefaction in the center of workpiece. Authors also analyze d the time-torque curve and the laws of load changing.

Galerkin-based quasi-smooth manifold element(QSME)method for anisotropic heat conduction problems in composites with complex geometry

The accurate and efficient analysis of anisotropic heat conduction problems in complex composites is crucial for structural design and performance evaluation. Traditional numerical methods, such as the finite element method(FEM), often face a trade-off between calculation accuracy and efficiency. In this paper, we propose a quasi-smooth manifold element(QSME) method to address this challenge, and provide the accurate and efficient analysis of two-dimensional(2D) anisotropic heat conduction problems in composites with complex geometry. The QSME approach achieves high calculation precision by a high-order local approximation that ensures the first-order derivative continuity.The results demonstrate that the QSME method is robust and stable, offering both high accuracy and efficiency in the heat conduction analysis. With the same degrees of freedom(DOFs), the QSME method can achieve at least an order of magnitude higher calculation accuracy than the traditional FEM. Additionally, under the same level of calculation error, the QSME method requires 10 times fewer DOFs than the traditional FEM. The versatility of the proposed QSME method extends beyond anisotropic heat conduction problems in complex composites. The proposed QSME method can also be applied to other problems, including fluid flows, mechanical analyses, and other multi-field coupled problems, providing accurate and efficient numerical simulations.

Self-adaptive one-dimensional nonlinear finite element method based on element energy projection method

The element energy projection （EEP） method for computation of super- convergent resulting in a one-dimensional finite element method （FEM） is successfully used to self-adaptive FEM analysis of various linear problems, based on which this paper presents a substantial extension of the whole set of technology to nonlinear problems. The main idea behind the technology transfer from linear analysis to nonlinear analysis is to use Newton＇s method to linearize nonlinear problems into a series of linear problems so that the EEP formulation and the corresponding adaptive strategy can be directly used without the need for specific super-convergence formulation for nonlinear FEM. As a re- sult, a unified and general self-adaptive algorithm for nonlinear FEM analysis is formed. The proposed algorithm is found to be able to produce satisfactory finite element results with accuracy satisfying the user-preset error tolerances by maximum norm anywhere on the mesh. Taking the nonlinear ordinary differential equation （ODE） of second-order as the model problem, this paper describes the related fundamental idea, the imple- mentation strategy, and the computational algorithm. Representative numerical exam- ples are given to show the efficiency, stability, versatility, and reliability of the proposed approach.

Stability assessment of landslide-prone road cut rock slopes in Himalayan terrain:A finite element method based approach

Large-scale slope destabilization could be aggravated due to swift urbanization and ever-rising demands of geoengineering projects such as dams,tunnels,bridges and widening roads.National Highway-58 connects Delhi to Badrinath in India,which passes through complex geomorphological and geological terrain and often encounters cut slopes susceptible to slope failures.In the present investigation,a detailed geotechnical appraisal is conducted along the road cut slopes from Rishikesh to Devprayag in the Himalayas.Twenty vulnerable road cut slopes were demarcated for detailed slope stability analysis using Phase2D finite element modeling simulator.Nonlinear generalized Hoek-Brown(GHB)criterion was adopted for stability analyses.Out of 20 slopes,five slopes(S6,S7,S18,S19 and S20)are unstable with factor of safety(FoS)less than or equal to 1,and thus needs immediate attention.The FoS values of four slopes(S2,S9,S13 and S17)lie between 1 and 1.3,i.e.marginally stable,and slopes S1,S3,S4,S5,S8,S10,Sll,S12,S14,S15 and S16 are stable.Mohr-Coulomb(MC)criterion was also adopted to compare the slope stability analysis with GHB criterion.The FoS calculated from GHB criterion is close to that using MC criterion for lower values of FoS whereas for higher values,the difference is marked.For the jointed rock in the Himalayan region,the nonlinear GHB criterion gives better results as compared to MC criterion and matches with the prevailing field conditions.Accordingly,some suggestions are proposed to strengthen the stability of cut slopes.

Mixed finite element and differential quadrature method for free and forced vibration and buckling analysis of rectangular plates

This paper presents a combined application of the finite element method （FEM） and the differential quadrature method （DQM） to vibration and buckling problems of rectangular plates. The proposed scheme combines the geometry flexibility of the FEM and the high accuracy and efficiency of the DQM. The accuracy of the present method is demonstrated by comparing the obtained results with those available in the literature. It is shown that highly accurate results can be obtained by using a small number of finite elements and DQM sample points. The proposed method is suitable for the problems considered due to its simplicity and potential for further development.

Self-adaptive strategy for one-dimensional finite element method based on EEP method with optimal super-convergence order

Based on the newly-developed element energy projection （EEP） method with optimal super-convergence order for computation of super-convergent results, an improved self-adaptive strategy for one-dimensional finite element method （FEM） is proposed. In the strategy, a posteriori errors are estimated by comparing FEM solutions to EEP super-convergent solutions with optimal order of super-convergence, meshes are refined by using the error-averaging method. Quasi-FEM solutions are used to replace the true FEM solutions in the adaptive process. This strategy has been found to be simple, clear, efficient and reliable. For most problems, only one adaptive step is needed to produce the required FEM solutions which pointwise satisfy the user specified error tolerances in the max-norm. Taking the elliptical ordinary differential equation of the second order as the model problem, this paper describes the fundamental idea, implementation strategy and computational algorithm and representative numerical examples are given to show the effectiveness and reliability of the proposed approach.

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.

SELF-ADAPTIVE STRATEGY FOR ONE-DIMENSIONAL FINITE ELEMENT METHOD BASED ON ELEMENT ENERGY PROJECTION METHOD

Based on the newly-developed element energy projection （EEP） method for computation of super-convergent results in one-dimensional finite element method （FEM）, the task of self-adaptive FEM analysis was converted into the task of adaptive piecewise polynomial interpolation. As a result, a satisfactory FEM mesh can be obtained, and further FEM analysis on this mesh would immediately produce an FEM solution which usually satisfies the user specified error tolerance. Even though the error tolerance was not completely satisfied, one or two steps of further local refinements would be sufficient. This strategy was found to be very simple, rapid, cheap and efficient. Taking the elliptical ordinary differential equation of second order as the model problem, the fundamental idea, implementation strategy and detailed algorithm are described. Representative numerical examples are given to show the effectiveness and reliability of the proposed approach.

Experimental and Finite Element Method Studies of J-Lead Solder Joint Reliability

A comprehensive experimental and numerical study of solder joints for plastic leaded chip carrier (PLCC) 84-Pin, 1.27 mm pitch was carried out. The reliability of solder joints was assessed through accelerated thermal cycling at the temperature range of - 55℃-125℃. The samples were taken out to observe the evolution in microstructure, such as grain coarsening, initiation and propagation of cracks. It was found that the Pb-rich phases segregated gradually and formed a continuous layer adjacent to the intermetallic compound (IMC) layer with increasing the number of thermal cycles, resulting in cracks near the solder/lead interface. The response of stress and strain was studied using nonlinear finite element method (FEM), and the results agreed well with the experimental data.

Radial Force Analysis of Polydioxanone Coronary Stent by Finite Element Method

Coronary stent is used to treat stenosis artery by recovering the luminal diameter of artery and maintaining the normal blood flow. The geometry of coronary stent is an important factor for the radial force. In this study,the relation between the radial force of stent and crown angle was discussed. The result showed that there was no particular rule between the radial force of stent and the crown angle. The maximum radial force of stent was obtained when the crown angle was 50. 04° and the minimum radial force was got when the crown angle was 75°.

P_1-nonconforming triangular finite element method for elliptic and parabolic interface problems

The lowest order Pl-nonconforming triangular finite element method （FEM） for elliptic and parabolic interface problems is investigated. Under some reasonable regularity assumptions on the exact solutions, the optimal order error estimates are obtained in the broken energy norm. Finally, some numerical results are provided to verify the theoretical analysis.

Modeling of contact surface morphology and dust particles by using finite element method

The effect of dust particles on electric contacts and a hazardous size range of hard dust particles using a rigid model were discussed before. As further research, elastic-plastic model of finite element analysis was established in this work, which is closer to real condition. In this work, the behavior of large size and small size particles, and the influence of particles hardness were investigated. The calculating result of small-size particles presents a general hazardous size coefficient for different contact surface morphology; for large-size particles, it presents a hazardous size coefficient for complicated composition of the dust. And the effect of the dust shape is also discussed.

Reduced-order finite element method based on POD for fractional Tricomi-type equation

The reduced-order finite element method （FEM） based on a proper orthogo- nal decomposition （POD） theory is applied to the time fractional Tricomi-type equation. The present method is an improvement on the general FEM. It can significantly save mem- ory space and effectively relieve the computing load due to its reconstruction of POD basis functions. Furthermore, the reduced-order finite element （FE） scheme is shown to be un- conditionally stable, and error estimation is derived in detail. Two numerical examples are presented to show the feasibility and effectiveness of the method for time fractional differential equations （FDEs）.

PREDICTION FOR FORMING LIMIT OF AL2024T3 SHEET BASED ON DAMAGE THEORY USING FINITE ELEMENT METHOD

This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.

Thermo-hydro-mechanical-air coupling finite element method and its application to multi-phase problems

In this paper, a finite element method （FEM）-based multi-phase problem based on a newly proposed thermal elastoplastic constitutive model for saturated/unsaturated geomaterial is discussed. A program of FEM named as SOFT, adopting unified field equations for thermo-hydro-mechanical-air （THMA） behavior of geomaterial and using finite element-finite difference （FE-FD） scheme for so/l-water-air three-phase coupling problem, is used in the numerical simulation. As an application of the newly proposed numerical method, two engineering problems, one for slope failure in unsaturated model ground and another for in situ heating test related to deep geological repository of high-level radioactive waste （HLRW）, are simulated. The model tests on slope failure in unsaturated Shirasu ground, carried out by Kitamura et al. （2007）, is simulated in the framework of soil-water-air three-phase coupling under the condition of constant temperature. While the in situ heating test reported by Munoz （2006） is simulated in the same framework under the conditions of variable temperature hut constant air pressure.

Finite cell method compared to h-version finite element method for elasto-plastic problems

The finite cell method （FCM） combines the high-order finite element method （FEM） with the fictitious domain approach for the purpose of simple meshing. In the present study, the FCM is used to the Prandtl-Reuss flow theory of plasticity, and the results are compared with the h-version finite element method （h-FEM）. The numerical results show that the FCM is more efficient compared to the h-FEM for elasto-plastic problems, although the mesh does not conform to the boundary. It is also demonstrated that the FCM performs well for elasto-plastic loading and unloading.

Determination of penetration depth at high velocity impact using finite element method and artificial neural network tools

Determination of ballistic performance of an armor solution is a complicated task and evolved significantly with the application of finite element methods(FEM) in this research field.The traditional armor design studies performed with FEM requires sophisticated procedures and intensive computational effort,therefore simpler and accurate numerical approaches are always worthwhile to decrease armor development time.This study aims to apply a hybrid method using FEM simulation and artificial neural network(ANN) analysis to approximate ballistic limit thickness for armor steels.To achieve this objective,a predictive model based on the artificial neural networks is developed to determine ballistic resistance of high hardness armor steels against 7.62 mm armor piercing ammunition.In this methodology,the FEM simulations are used to create training cases for Multilayer Perceptron(MLP) three layer networks.In order to validate FE simulation methodology,ballistic shot tests on 20 mm thickness target were performed according to standard Stanag 4569.Afterwards,the successfully trained ANN(s) is used to predict the ballistic limit thickness of 500 HB high hardness steel armor.Results show that even with limited number of data,FEM-ANN approach can be used to predict ballistic penetration depth with adequate accuracy.

Genetic algorithm-finite element method inversion of the factors determining the recent tectonic stress field of part of East Asia area

Genetic algorithm finite element method (GA FEM) is applied to the study of tectonic stress field of part of East Asia area. From the observed stress distribution, 2 D elastic plane stress inversion is made to deduce the boundary forces and investigate controlling factors. It is suggested that the continent continent collision is the dominant factor controlling the Chinese tectonic stress field. The ocean continent convergence along the subduction zone is an important factor. There exists tensile boundary force along the marginal sea.

A Numerical Method for Rigid-plastic FEM Analysis Basing on Mathematical Programming

The rigid-plastic analysis of mental forming simulation is formulated as a discrete nonlinear mathematical programming problem with equality and inequality constraints by means of the finite element technique. An iteration algorithm is used to solve this formulation, which distinguishes the integration points of the rigid zones and the plastic zones and solves a series of the quadratic programming to overcome the difficulties caused by the nonsmoothness and the nonlinearity of the objective function. This method has been used to carry out the rigid-plastic FEM analysis. An example is given to demonstrate the effectiveness of this method.

Dynamic Analysis of a Centrifugal Compressor by Finite Element Method

This paper mainly deals with dynamic analysis of rotor-bearing system in a centrifugal compressor. A finite element model of the rotor-bearing system has been developed. The considered factors of the model include the rotary inertia of solid elements, stiffness and damping of hydrodynamic bearing. In the calculating, ANSYS software was used. Both calculated and measured results are in good agreement.