DEVELOPMENT OF COMPUTER SIMULATION SOFTWAREON PHASE TRANSFORMATION DURING QUENCHING

A computer software to simulate the phase transformation during quenching is designed based on Avrami equation and Scheil additivity principle of incubation period. The isothermal transformation diagrams of supercooled austenite are described by cubic spline functions. This software is possess of a good graphic interface of Windows style, can simulate the whole process in austenite decomposition during continuous cooling. If the cooling rate was given, the fraction of various microstructures transformed of austenite decomposition during continuous cooling at any temperature can be calculated. The simulation results are checked with the quenching experiment of 45 steel. The results indicate that the simulation results are comparatively close to the experimental results.

基于DEM-FEM耦合的环锤式破碎机反击板可靠性分析

由于环锤式破碎机破碎物料的过程是一个极其复杂多变的过程,且与反击板所受的碰撞力是不连续、无规则的,因此,无法使用公式推导或使用单一软件对反击板受力进行计算,为了能够更好地确定破碎机破碎过程中反击板的载荷大小、分布和寿命,文中提出了一种基于离散元(DEM)和有限元(FEM)耦合计算的环锤式破碎机反击板可靠性分析方法,通过EDEM建立环锤式破碎机破碎物料仿真过程,并提取出破碎过程中反击板的载荷分布,与ANSYS Workbench建立耦合计算通道,计算得到在正常工作参数下反击板的受力大小和位置,在此基础上采用n Code Design Life疲劳分析软件对反击板进行寿命分析,得到反击板的受力云图和损伤云图,研究转子转速、反击板倾角、转子与筛板距离等不同因素下对反击板可靠性的影响,结果表明:转子转速为1000 r∕min时反击板的最大受力值为247.9 MPa、反击板角度为60°时应力最大值为206.48 MPa、转子与筛板距离为530 mm时受力最大值为268.37 MPa。

基于SPH-FEM算法的森林灭火弹爆炸抛撒灭火剂初速的数模拟研究

针对森林灭火弹爆炸抛撒问题,应用LS-DYNA软件对森林灭火弹爆炸抛撒灭火剂初速进行数值模拟研究。依据森林灭火弹爆炸抛撒实验的数据,对Gurney公式进行修正;建立森林灭火弹的仿真模型,将仿真模型所得灭火剂初速与修正后Gurney公式所得灭火剂初速进行对比,验证SPH-FEM耦合算法研究此类问题的可行性;对森林灭火弹装药结构进行优化,分析阶梯装药结构对灭火剂初速的影响。结果表明,修正后Gurney公式能够更好地适用于灭火剂初速的计算;采用SPH-FEM耦合算法模拟所得灭火剂初速与修正后Gurney公式所得灭火剂初速的吻合度高,表明采用SPH-FEM耦合算法研究此类问题是可行的;对森林灭火弹装药结构进行阶梯化改进可以增大灭火剂抛撒面积与提升灭火剂抛撒均匀性,提高森林灭火弹灭火效率。

Computer Simulation on Metallic Card Clothing Garnett Wire Teeth's Temperature Field & Structure Field in the Process of Quenching Treatment

The quenching process of garnett wire teeth of metallic card clothing heated by flame was researched by use of 3-D finite element method and the equation of boundary condition was established by making use of a model of artificial neural network. The transient temperature field, phase transformation in the heating process, the quenching microstructures and the hardness distribution on quenched garnett wire teeth of metallic card clothing were simulated. The result shows that the maximum error of the hardness between the simulative value and the actual measuring value is 8.0% on only one testing point and errors are all less than 3.0% on other testing points.

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.

Simulation and experimental study of 7A09 aluminum alloy milling under double liquid quenching

To explore the influence of double liquid quenching on the cutting performance of the 7A09 aluminum alloy,quasi-static compression and dynamic impact tests were carried out on the 7A09 aluminum alloy after double liquid quenching using an MTS810.23 universal testing machine and split-Hopkinson pressure bar(SHPB).The experimental data were fitted to obtain the Johnson–Cook constitutive model parameters of the alloy.Simulations of the machining process were carried out using the Deform-3D finite element software.The results showed that the rheological stress increased with the increase in strain rate and the decrease in temperature.The increase in the cutting speed and feed caused the cutting temperature to rise sharply,whereas the influence of the cutting amount on the cutting temperature was weak.Because of the presence of chip nodules,there was extremum in the cutting force vs cutting speed curves.The increase in the feed and cutting depth increased the cutting area Ac,so the cutting force also increased.The simulation results were verified by experiments.The simulation predictions were in good agreement with the test values,and the cutting force and temperature variations with the cutting parameters were the same.Thus,the correctness of the 7A09 aluminum alloy finite element model was verified.

Modeling and Identification of Anisotropic Damping Property of Ni-Based Alloys by FEM-Simulation

The modeling and identification of anisotropic damping property of Ni based single crystal alloys are presented. The anisotropic material damping property is modeled by 3 D rheological equations and identified by using specimen modal damping ratios and FEM simulation. The measured damping ratios which exhibit strong anisotropy are predicted better by the method presented than by other methods.

Numerical Simulation on Carburizing and Quenching of Gear Ring

The carburizing process of the gear ring was simulated by taking into account the practical carburizing and quenching techniques of the gear ring and by solving the diffusion equation. The carbon content distribution in the carburized layer was obtained. Based on the results, the quenching process of the gear ring was then simulated using the metallic thermodynamics and FEM： it was found that the carburization remarkably affects the quenching process. Microstructures and stress distributions of the gear ring in the quenching process were simulated, and the results are confirmed by experiments.

COUPLED NUMERICAL SIMULATION ON COLD ROLLER'S TEMPERATURE FIFLD-PHASE TRANSFORMATION - STRESS FIELD DURING ITS QUENCHING PSOCESS

Complicated changns occur inside the steel parts during quenching process. The abruptly changed boundary conditions make the temperature field,micro - structure and stress field change dramatically in very short time, and these variables take a contact interactions in the whole process. In this paper, a three dimensional non - linear mathematical model for queeching process has been founded and the numerical simulation on temperature field,microstructre and stress field has been realized.In the FEM analysis, the incremental iteration method is used to deal with such complicated nonlinear as boundary nonlinear, physical property nonlinear,transformation nonlinear etc.The effect of stress on transformation kinetics has been considered in the calculation of microstructure. In the stress field anal- ysis,a thermo- elasto - plastic model has been founded, which considers such factors as transforma- tion strain,transformation plastic strain, themal strain and the effect of temperature and transforma- tion on mechanical propertier etc. The transient temperature field, microstructure distribution and stress field of the roller on any time can be displayed vividly,and the cooling curve and the changes of stress on any position can also be given.

FEM Simulation of Welding Quality in Porthole Die Extrusion

The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.

基于SPH-FEM方法的土中浅埋爆炸成坑效应研究

通过设计开展静爆实验,对土中浅埋爆炸成坑效应及影响因素进行研究。基于所获取的静爆试验数据,建立SPH-FEM数值模型,对土中浅埋爆炸过程及爆坑参数进行分析,验证SPH-FEM方法模拟土中浅埋爆炸的有效性。进一步通过数值计算对比,讨论了SPH-FEM方法与ALE方法在土中爆炸数值模拟过程中的异同、爆坑半径与炸药埋设深度的关系以及炸药量与爆坑体积的关系,并通过数学拟合得到了9.35 kg TNT条件下,炸药埋设深度与爆坑半径的经验曲线公式。研究表明:SPH-FEM方法较ALE方法模拟土中浅埋爆炸更加精细且计算效率更高。所建立的炸药埋设深度与爆坑半径的经验曲线公式可以有效预测浅埋爆炸的爆坑半径,且随着炸药埋设深度的增加,爆坑半径将先随之增大到峰值,之后爆坑半径将会随炸药埋设深度的增加而迅速减小。

3D FEM Simulation of Milling Force in Corner Machining Process

To optimize milling force and machining accuracy quality in corner milling process, the changing law of milling force is revealed by Finite Element Method（FEM）. Based on DEFORM software a serial of 3D FEM models for corner milling process are devloped. Tool curved trajectory is achieved by establishing accurate relationship of tool location with milling time. Adaptive remeshing technique and iterative algorithm are adopted to ensure convergence of FEM model. Component force characteristics are revealed by analyzing FEM simulation results. It indicates that the milling force in Y direction becomes negative comparing with forces in X and Z direction. Magnitude of forces in three directions decreases with increase of spindle speed, while it increases with increase of milling feedrate. The simulation results for cutting force are in good agreement with those obtained from experiment. The FEM simulation model is first successfully established for corner milling process in this study, and the results provide a guide for optimizing cutting parameters in cutting process.

FEM simulation of aluminum extrusion process in porthole die with pockets

In order to investigate the effects of pockets in the porthole die on the metal flow,temperature at the die bearing exit and the extrusion load were contrasted with the traditional die design without the pockets in the lower die.Two different multi-hole porthole dies with and without pockets in lower die were designed.And the extrusion process was simulated based on the commercial software DEFORM-3D.The simulation results show that the pockets could be used to effectively adjust the metal flow and especially benefit to the metal flow under the legs.In addition,the maximum temperature at the die bearing and the peak extrusion load decrease,which indicates the possibility of increasing the extrusion speed and productivity.

Quantitative Prediction of Fracture Distribution of the Longmaxi Formation in the Dingshan Area, China using FEM Numerical Simulation

Fracture prediction is a technical issue in the field of petroleum exploration and production worldwide.Although there are many approaches to predict the distribution of cracks underground,these approaches have some limitations.To resolve these issues,we ascertained the relation between numerical simulations of tectonic stress and the predicted distribution of fractures from the perspective of geologic genesis,based on the characteristics of the shale reservoir in the Longmaxi Formation in Dingshan;the features of fracture development in this reservoir were considered.3 D finite element method(FEM)was applied in combination with rock mechanical parameters derived from the acoustic emissions.The paleotectonic stress field of the crack formation period was simulated for the Longmaxi Formation in the Dingshan area.The splitting factor in the study area was calculated based on the rock breaking criterion.The coefficient of fracture development was selected as the quantitative prediction classification criteria for the cracks.The results show that a higher coefficient of fracture development indicates a greater degree of fracture development.On the basis of the fracture development coefficient classification,a favorable area was identified for the development of fracture prediction in the study area.The prediction results indicate that the south of the Dingshan area and the DY3 well of the central region are favorable zones for fracture development.

Numerical Simulation of Thermal Stress Fields in the Magnetic Quenching Process of 45 Steel

Based on a transient temperature distribution of a 45 steel cylinder workpiece during magnetic quenching, which was obtainedby solving the governing equations with nonlinear boundary on the condition of coupling effects of heat-magnetism. Accordingto the theory of thermal non-elasticity, computational mechanics, ferromagnetism and phase transformation, a new constitutiveequation considering effects of phase transformation is proposed and solved by means of finite element method. The transientthermal stress and residual stress are obtained and the influencing factors on the thermal stress of magnetic field are analyzedand discussed.

FEM Simulation of the Hydroforming Process of Spherical Vessels from Combination Frustum Shells

The dieless hydroforming of spherical vessels from combination frustum shells is put forward in the present paper,and the forming process is developed by means of elastoplastic finite element method and experiments.In this paper the principle and experimental procedure of the new technology are introduced,the simulation method and the calculating assumptions are presented,the deformation process and the deformation characteristics of the shells are discussed,as well as the stress and strain distributions of the shell during bulging are analysed.

Ductile damage and simulation of fine-blanking process by FEM

Based on the Curson Tvergaard void damage plastic potential equation and by using orthogonal rules of plastic material, the influence of void volume fraction on stress and strain fields was introduced into Levy Mises flow rules. The variation principle of rigid plastic material with void degradation was demonstrated. Furthermore, FEM equations coupled with damage factor were presented to study the void growth and the criterion to judge the damage was also given. Using the developed system, the fine blanking process was simulated and the sheared surface of the part edge was predicted. Meanwhile, the influence of process parameters, such as punch die clearance, V ring force, counter force, radius of punch and die edges, on the height and quality of the sheared surface was analyzed. The calculation results were compared with the experiments, which can be used to guide the design of fine blanking process.

FEM SIMULATION AND EXPERIMENTAL RESEARCH ON THE SHEET BLANKING

Both experiment and simulation are made on the AlMg4 . 5Mn0 .4 sheet blanking with 1 % , 10% and 20% relative clearance respectively. The cutting force curves and the cutting surface parameters which can be used to describe the quality of the blankings are measured. Simulation is accomplished by MARC Autoforge software package. Calculated cutting forces are always bigger than measured ones. All difference between experiment and simulation is not greater than 20% . It is feasible making virtual experiment on workstation to estimate the cutting force and to predict the quality of the workpiece for new material using certain blanking technical parameters.

HEXAHEDRAL ELEMENT REFINEMENT FOR THE PREDICTION- CORRECTION ALE FEM SIMULATION OF 3D BULKINGFORMING PROCESS

Based on the characteristics of 3D bulk forming process, the arbitrary Lagrangian-Eulerian (ALE) formulation-based FEM is studied, and a prediction-correction ALE-based FEM is proposed which integrates the advantages of precisely predicting the boundary configuration of the deformed material, and of efficiently avoiding hexahedron remeshing processes. The key idea of the prediction-correction ALE FEM is elaborated in detail. Accordingly, the strategy of mesh quality control, one of the key enabling techniques for the 3D bulk forming process numerical simulation by the prediction-correction ALE FEM is carefully investigated, and the algorithm for hexahedral element refinement is formulated based on the mesh distortion energy.

FEM Simulation on Artificial Freezing of Seepage Ground

The coupling mechanism in freezing process of seepage ground was studied and a simplified coupling math model was proposed. The nonlinear and coupling problems of PDEs were well solved using the exponential function, error function and normal distribution function, and a series of FEM equations of coupled fields of temperature and seepage were deduced and put forward. With the example of shaft ground freezing, the formation of freezing wall in seepage ground was simulated.