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.

Effect of annealing on the microstructures and Vickers hardness at room temperature of intermetallics in Mo-Si system

The microstructures and Vickers hardness at room temperature of arc-meltingprocessed intermetallics of Mo_5Si_3-MoSi_2 hypoeutectic alloy and hypereutectic alloy annealed at1200℃ for different time were investigated. Lamellar structure consisted of Mo_5Si_3 (D8m) phaseand MoSi_2 (C11_b) phase was observed in all the alloys. For Mo_5Si_3-MoSi_2 hypoeutectic alloy, thelamellar structure was found only after annealing and developed well with fine spacing on the orderof hundred nanometers after annealing at 1200℃ for 48 h. But when the annealing time was up to 96h, the well-developed lamellar structure was destroyed. For Mo_5Si_3-MoSi_2 hypereutectic alloy, thelamellar structure was found both before and after annealing. However the volume fraction andspacing of the lamellar structure did not change significantly before and after annealing. Theeffects of the formation, development and destruction of lamellar structure on Vickers hardness ofalloys were also investigated. When Mo_5Si_3-MoSi_2 hypoeutectic alloy annealed at 1200℃ for 48 h,the Vickers hardness was improved about 19% compared with that without annealing and formation oflamellar structure. The highest Vickers hardness of Mo5Si3-MoSi_2 hypereutectic was increasing about18% when annealing at 1200℃ for 48 h.

Process of Microcellular Propellants with Adjustable Skin Thickness

Microcellular propellants show a vast applicable prospect due to their special shell-pore structure. The effects of saturation pressure and desorption time on skin thickness are studied. The skin thickness is observed and measured using scanning electron microscope (SEM). The results show that the skin thickness decreases when saturation pressure increases from 15 MPa to 30 MPa. In contrast, the skin thickness increases as the desorption time changes from 2 min to 20 min.Therefore, the microcellular propellants with adjustable skin thickness can be obtained under the variable process conditions such as saturation pressure and desorption time.

Primary study of the isothermal phase diagram of the Cu_2O-Al_2O_3-SiO_2 ternary system at 1150℃ in air

The isothermal phase diagram of the Cu2O-Al2O3-SiO2 ternary system at 1150℃ was reported for the samples which were prepared from sol-gel method and quenched by water after being heated at 1150℃ for 12 h. Based on the conventional X-ray powder diffraction （XRD） and in situ high-temperature XRD quantitative analysis,in addition to scanning electron microscopy measurement,the phase identification was achieved. Combining the deduction from the component phase diagrams of the binary systems using the phase equilibrium theorem,the primary isothermal phase diagram was plotted over the composition area Cu2O-mullite-SiO2. In this area,the approximate composition areas of two two-phase regions and one three-phase region,（L2＋Cr）,（L2＋M）,and （L1＋L2＋Tr）,were determined. Moreover,the precise composition areas of both of the three-phase regions （L2＋Cr＋M） and （L2＋M＋A） were determined according to the results of conventional and in situ high-temperature XRD quantitative analysis by Rietveld method.