Coupled mechanical and thermal simulation of warm compaction

Warm compaction process of pure iron powder was investigated. Due to the existence of elastic, plastic and thermal strains, a coupled mechanical and thermal model was applied. The elasto-plastic constitutive equations for powder material were developed based on ellipsoidal yield criterion and continuum theory. The constitutive equations were integrated into the constitutive integral arithmetic and solved employing incremental iterative solution strategy. The yield strength of iron powder was obtained according to the tensile experiments. When the compaction temperature was raised to 130 ℃, the yield strength of iron powder metal drops to 85% of room temperature value. Modified coulomb friction law is applied and the simulation results show that friction was an important factor resulting in the inhomogeneous relative density and reverse-density distribution phenomena in the regions near the die wall and the symmetrical axis.

FINITE ELEMENT SIMULATION AND OPTIMIZATION OF MULTISTAGE WARM/HOT FORMING FOR OUTER RACE

A multistage warm/hot forming is simulated for the cross grove outer race ofconstant velocity joint, using a thermo-mechanical coupled rigid viscoplastic finite element method,and specially some problem for process development and die design are analyzed. A forming testshows that computed results have good agreement with experimental results. Above obtained resultscan be applied to development of multistage warm/hot forming process and die design for outer race.

Numerical simulation of tire/soil interaction using a verified 3D finite element model

The compaction and stress generation on terrain were always investigated based on empirical approaches or testing methods for tire/soil interaction.However,the analysis should be performed for various tires and at different soil strengths.With the increasing capacity of numerical computers and simulation software,finite element modeling of tire/terrain interaction seems a good approach for predicting the effect of change on the parameters.In this work,an elaborated 3D model fully complianning with the geometry of radial tire 115/60R13 was established,using commercial code Solidwork Simulation.The hyper-elastic and incompressible rubber as tire main material was analyzed by Moony-Rivlin model.The Drucker-Prager yield criterion was used to model the soil compaction.Results show that the model realistically predicts the laboratory tests outputs of the modeled tire on the soft soil.

Real-time determination of sandy soil stiffness during vibratory compaction incorporating machine learning method for intelligent compaction

An emerging real-time ground compaction and quality control, known as intelligent compaction(IC), has been applied for efficiently optimising the full-area compaction. Although IC technology can provide real-time assessment of uniformity of the compacted area, accurate determination of the soil stiffness required for quality control and design remains challenging. In this paper, a novel and advanced numerical model simulating the interaction of vibratory drum and soil beneath is developed. The model is capable of evaluating the nonlinear behaviour of underlying soil subjected to dynamic loading by capturing the variations of damping with the cyclic shear strains and degradation of soil modulus. The interaction of the drum and the soil is simulated via the finite element method to develop a comprehensive dataset capturing the dynamic responses of the drum and the soil. Indeed, more than a thousand three-dimensional(3D) numerical models covering various soil characteristics, roller weights, vibration amplitudes and frequencies were adopted. The developed dataset is then used to train the inverse solver using an innovative machine learning approach, i.e. the extended support vector regression, to simulate the stiffness of the compacted soil by adopting drum acceleration records. Furthermore, the impacts of the amplitude and frequency of the vibration on the level of underlying soil compaction are discussed.The proposed machine learning approach is promising for real-time extraction of actual soil stiffness during compaction. Results of the study can be employed by practising engineers to interpret roller drum acceleration data to estimate the level of compaction and ground stiffness during compaction.

Finite-Element Simulation and Experimental Research of the Hot-Press Sintering of Nano-Sized Ceramic Powders

Numerical simulation of hot-press sintering of nano-sized ceramic powders was introduced by the commercial finite element code MSC.MARC. The powder plastic model and the thermo-mechanical coupled quadrilateral element were developed and adopted in the simulation. The mechanical and thermal properties of the nano-sized alumina based powders were determined.In addition, the experimental research and numerical simulation of the sintering process of different initial densities were carried out. The stress state in sintering of green compacts with different initial densities was analyzed by the densification theory.The reason for the density fluctuations of as-sintered ceramic bulks was found out.

翁结水库碾压混凝土重力坝动力特性及其抗滑稳定分析

重力坝是水利工程中最常用的主要水工建筑物之一,混凝土重力坝在地震作用下的动力稳定是坝工设计中的重要问题.本文以翁结碾压混凝土重力坝为对象,取位于河谷中的7、8号溢流坝段和9号非溢流坝段,建立三维有限元模型,通过计算分析了碾压混凝土重力坝在不同工况下的应力变形规律及抗滑稳定性.结果表明:静力荷载作用下,坝体位移符合重力坝一般规律,坝踵主拉应力范围较小;动力荷载作用下,位移等响应在坝顶达到最大,符合鞭鞘效应特征,同时坝体残余位移较小,坝体在一些部位出现瞬时拉应力超标现象,坝基塑性区未发生贯通;对7、8号坝段和9号坝段在建基面及碾压层面进行抗滑稳定验算,坝体坝基均满足稳定要求.

基于PFEM法的黄土地基振杆密实过程大变形分析

采用粒子有限元方法(PFEM)及结构性土的本构模型,对振杆密实法加固砂质黄土地基的大变形过程进行了数值模拟研究,分析了振杆贯入过程中周围土体的位移场、应力场、速度场以及塑性体应变等分布规律,揭示了砂质黄土地基深层振动密实机理.结果表明:现场实测和数值模拟获得的地面垂直振动速度峰值变化趋势较为一致,验证了粒子有限元方法的可靠性;垂直激振的振杆能够同时引起土体垂直方向和水平方向上位移场、应力场和速度场的变化;在距振源水平距离5R(R为振杆半径)范围内,土颗粒以半梭形向外扩展并趋于密实,同时水平应力大幅增加并产生预压效果;以塑性体应变作为加固范围的评价标准,结果表明土体径向加固范围随振杆贯入深度增加而略有增大,最大径向加固范围约为3.2R,且振杆底端以下1R~2R范围亦有密实效果.

数值模拟在粉末压制细观分析中的应用与发展

数值模拟技术已经成为研究粉末压制过程的重要手段。研究人员运用离散单元法(discrete element method,DEM)从细观角度研究粉末颗粒的力学行为,分析力链特性及力链演化过程,揭示细观结构对宏观性质的影响;使用多粒子有限元法(multi-particle finite element method,MPFEM)从颗粒层面对不同粉末的压制变形机理进行研究。本文对离散单元法和多粒子有限元法两种数值模拟方法在粉末压制中的应用及发展进行综述,总结了多粒子有限元法在粉末压制数值模拟中的难点,分析得到在动态载作用下对粉末力链演化规律及颗粒致密机理的研究可作为未来探索方向的展望。

Simulation of die wall friction's effect on density distribution in metallic powder compaction

A computer simulation procedure for metal powder die compaction was described. Friction behavior of metal powder during cold compaction was simulated by the finite element method. The movement of powder relative to the die wall was taken into consideration by utilizing the shear friction model. Friction between the powder and the rigid die wall leads to inhomogeneous density distribution during the compaction process. The floating die technique and double punch pressing can attain more homogenous compacts than the fixed die technique can do. The results obtained from numerical analysis agree well with the experimental results. Simulation model was built in MSC.Mentat, and MSC.Marc software was used to calculate the powder compaction process.

Research of PDC Bit Compact Die With FEM and Optimum Method

In mould design, it is necessary for a designer to ensure that the cylinder has enough intensity in both the prestressed and synthesis states. An individual layer cylindrical mould cannot withstand a very high pressure needed in polycrystalline diamond composite (PDC) production. So, multi-layer prepressure combination assemble moulds are often used. The analysis conducted here is to study the interaction of cylindrical layers and to explain how to obtain enough load capability with the lowest requirement of material performance. The ratio of the pressure cylinder radius of synthetic diamond is 3.27, which is close to the optimal value and can be used as structure size in a design for PDC bit compact die. There is a linear relationship between the internal and external pressures under a special tangent stress on the inner wall of the pressure cylinder. So, when two of the three parameters (the internal pressure, external pressure, and the requirement value of the tangent stress on the inner wall of the pressure cylinder) are given, the third can be obtained. The sleeve acts as a bridge?between the pressure cylinder and the steel belts. The optimum model developed in this paper can be used in PDC bit compact die design and other similar prestressed cold extrusion die design.

Numerical simulation of warm compacted synchronous pulley

A new mechanical model for warm powder compaction was presented. Warm compaction process of iron-based powder was investigated to deal with the existence of elastic, plastic and thermal strains. A coupled mechanical and thermal model was developed based on ellipsoidal yield criterion and continuum theory. The constitutive equations were integrated into the constitutive integral arithmetic and solved employing incremental iterative solution strategy. The flow stress model of iron powder was nonlinearly fitted according to uniaxial warm compaction. The constitutive model was implemented into user-subroutines of MSC.Marc. With the equations, algorithms and programs developed, the compaction procedures of a complex synchronous pulley were simulated. Two different compaction schemes with different punch displacements were tested and the relative density distribution was obtained. Comparison with experimental data shows that the homogeneity of green compact is greatly affected by the compaction mode. The simulation results agree with the experiments very well.

The Compactions of Elasto-Plastic and Visco-Plastic Granular Assemblies

In this paper, the compactions of the elasto-plastic and the visco-plastic granular assemblies are simulated using the finite element method. Governing equations for motion and deformation for particles, including coupling of rigid body motion and deformation for deformable bodies, are investigated. An implicit discrete element method for block systems is developed to make visco-plastic analysis for the assemblies. Among particles, three different contact types, cohering, rubbing and sliding, are taken into account. To verify accuracy and efficiency of the numerical method, some numerical example is simulated and the results are in a satisfactory agreement with the solutions in literatures. The effects of frictional condition, the initial solid volume ratio, the number of particles in the assembly, and different types of compact- tion on the compaction of the elasto-plastic and the visco-plastic aggregates are investigated. It is demonstrated that the effect of frictional condition, the initial solid volume ratio, the number of particles in the assembly, and different types of compaction on the global behavior of the elasto-plastic the visco-plastic granular assemblies under compacting are considerable. The numerical model is extended to simulate the compaction of aggregates consisting of mixed particles of different viscous incompressible materials. It is indicated that, with minor modification, the method could be used in a variety of problems that can be represented using granular media, such as asphalt, polymers, aluminum, snow, food product, etc.

XFEM和修正剑桥模型模拟高聚物劈裂注浆方法研究

针对自膨胀高聚物材料在土体中劈裂扩散仿真手段尚不完备的现状,初步建立了一种模拟高聚物对土体劈裂压密作用的仿真方法。该方法采用扩展有限元离散求解区域土体介质,用修正剑桥模型描述土体力学特性,利用高聚物密度-围压关系迭代计算作用于裂缝面的浆液膨胀压力,实现了对土体劈裂缝扩展过程的数值模拟,通过与试验结果的对比验证了该方法的适用性。算例分析表明,应用该方法能够模拟膨胀力作用下土体裂缝启裂过程、扩展走向和浆脉厚度变化,获得裂缝周围土体变形模量、孔隙比、应力场和密度场分布特征,为深入研究膨胀性高聚物注浆材料对土体劈裂压密机制奠定了基础。

双层水泥稳定碎石基层层间压实度差异对基层整体性能的影响

【目的】研究双层水泥稳定碎石基层上下层压实度差异对基层性能的影响。【方法】首先对层间不同水灰比及水泥浆剂量的试件进行直接剪切试验和直接拉伸试验,得到最佳水泥浆剂量及水灰比;在此基础上,研究了上下层层间压实度差异对水泥稳定碎石基层整体无侧限抗压强度、抗弯拉强度及疲劳寿命的影响;最后,利用有限元软件ABAQUS模拟分析了不同上下层压实度差下路表弯沉和各结构层层底弯拉应力。【结果】通过试验得到水泥稳定碎石基层层间最佳水泥浆剂量和水灰比分别为0.311 g/cm^(2)和1∶1.5,提高基层整体压实度并降低基层上下层压实度差能够提高水泥稳定碎石基层的整体力学强度和疲劳性能,进而降低路表弯沉和提高基层疲劳寿命。【结论】减小水泥稳定碎石基层上下层压实度差能够显著提高基层的力学强度及耐久性。

观音水库重力坝设计及有限元分析

采用有限元对观音水库重力坝的安全进行复核,得到大坝各工况下的结构应力、变形及坝基抗滑稳定安全系数,并与传统材料力学法和刚体极限平衡法的计算结果进行对比验证,证明大坝设计的正确性和合理性。对于坝基软弱结构面、坝体局部孔口削弱部位,有限元分析的成果也为后续设计提供了依据。

不同压制工艺对粉末冶金制品性能影响的有限元模拟

利用MSC/MARC有限元分析软件对金属粉末压制过程进行模拟分析。采用基于更新拉格朗日方法的热—力耦合分析不同工艺条件(温度、摩擦条件和压制方式等)对压坯性能的影响规律,同时对压制过程中的力学特征(压制力、脱模力、侧压力和应力分布等)进行分析。结果显示,摩擦条件是影响压坯密度大小及分布的关键因素,通过采用双向压制方法可以有效地改善单向压制压坯密度分布不均、差值较大的现象。温度的提高有利于提高粉末颗粒的塑性变形能力,但效果不明显。另外,由于温度影响润滑剂润滑性能,因此在制定压制工艺时需考虑温度对压坯性能的影响。此外温度的提高、摩擦的降低均有利于降低压制力,提高压坯密度均匀性,改善压坯应力集中现象。

新型外转子磁齿轮复合电机的设计与研究

提出一种新型外转子磁齿轮复合电机,该电机将磁齿轮和无刷直流电机进行整合,电机的外转子和磁齿轮的内转子共同构成复合电机的内转子,实现了低速大转矩的直接驱动方式,同时充分利用了磁齿轮的内部空间,从而提高了整个传动系统的效率。采用时步有限元法对复合电机的磁场进行分析,充分考虑了谐波磁场的相互耦合问题,并得出复合电机的相关动态特性。这些特性揭示了复合电机非常适合与低速大转矩的直接驱动场合,但是不适合于对舒适度和位置精度要求较高的场合。制造了一台1200W原型机,并对原型机进行试验,验证了电磁理论分析结果的正确性。

小型拖拉机土壤压实的有限元预测

农业土壤的基本特征是松软和经常处于非饱和状态 ,土壤体积密度与含水率既是主要参数又是影响压实的重要因素 ,且在不断地变化。为了进行有效田间土壤压实管理 ,根据具体土壤特性 ,采用一个二维的模型 ,用有限元方法进行土壤压实预测。模型考虑了应力路径、初始土壤体积密度和含水率等 ,将土壤体积密度视为平均主应力和最大自然剪切应变的非线性函数 ,可预测小型拖拉机在非饱和土壤上通过时引起土壤体积密度的变化及应力分布情况等。在华北轻壤土的试验证明 。

粉末温压中模具的加热设计及有限元热场分析

为解决粉末温压设备的加热问题,本文通过理论分析和计算采用电加热方式,根据实际需要设计并选择合理可行的模具加热装置.利用有限元前后置处理软件MSC.Patran及分析软件MSC.Marc对温压模具进行热场分析,模拟了模具的温度场状况.通过实验验证了所提出的设计方案及采用有限元分析的可行性.

特高压紧凑型输电线路工频电场强度计算

为研究特高压交流输电线路的工频电场强度,通过建立二维静电场有限元模型,计算了LGJ-400/65、LGJ-500/45、LGJ-630/45 3种型号导线,子导线根数分别为6、8、10、12的导线表面场强、相导线平均场强最大值、线路下方距地面1 m处最大场强和线路走廊宽度,分析了导线截面、子导线根数、线路最低对地高度和走廊宽度的选取。结果表明特高压交流线路选取大截面导线、紧凑型倒三角布置方式在导线表面场强、杆塔高度和线路走廊方面可满足要求。