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 a...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.展开更多
Extended finite element method(XFEM) is proposed to simulate the discontinuous interface in the liquid-solid forming process.The discontinuous interface is an important phenomenon happening in the liquid-solid forming...Extended finite element method(XFEM) is proposed to simulate the discontinuous interface in the liquid-solid forming process.The discontinuous interface is an important phenomenon happening in the liquid-solid forming processes and it is difficult to be simulated accurately with conventional finite element method(CFEM) because it involves solid phase and liquid phase simultaneously.XFEM is becoming more and more popular with the need of solving the discontinuous problem happening in engineering field.The implementation method of XFEM is proposed on Abaqus code by using UEL(user element) with the flowchart.The key is to modify the element stiffness in the proposed method by using UEL on the platform of Abaqus code.In contrast to XFEM used in the simulation of solidification,the geometrical and physical properties of elements were modified at the same time in our method that is beneficial to getting smooth interface transition and precise analysis results.The analysis is simplified significantly with XFEM.展开更多
The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/stra...The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.展开更多
A three-dimensional finite element thermal model in direct metal laser sintering(DMLS) including the effect of powder-to-solid transition were established to predict sintering zone, which benefited the determination o...A three-dimensional finite element thermal model in direct metal laser sintering(DMLS) including the effect of powder-to-solid transition were established to predict sintering zone, which benefited the determination of suitable process parameters in DMLS. The nonlinear transient model of the metals thermal conductivity for powder-to-solid transition was developed. The model uses solid thermal properties of material in liquid-phase zone, transitional ones in sintering or sintered zone and powder ones in unsintered zones of powder bed to predict, respectively. Sintering zone boundary was estimated by maximum temperature history profile. Experiments were carried out using multi-component Cu-based metal powder. Compared experimental and predicted results, the mean error of sintering depth and width are 7.8% and 14.4%, respectively, which confirms the accuracy of the FEM prediction.展开更多
The investigation on hydrodynamic characteristics of a cage is important for its application in the deep-sea aquaculture in our country.With finite element method,the beam element is used to simulate a three-dimension...The investigation on hydrodynamic characteristics of a cage is important for its application in the deep-sea aquaculture in our country.With finite element method,the beam element is used to simulate a three-dimensional metal chain net,and the connector element is introduced as the interaction between metal net lines.A mechanical model for the metal net is constructed to simulate the hydrodynamic characteristics of a metal net subjected to fluid current forces.The static simulation results show that the relative errors of the displacements are 2.13%,4.19%,6.64%,and 11.35% compared with static concentrated load tests under concentrated forces of 20,40,60,and 80 N,respectively.Both the transient hydrodynamic deformations and drag forces of the netting structures under different current velocities are obtained by solving the hydrodynamic equation of the netting structure.The average relative error of the current forces obtained by numerical simulations shows an 8.13%deviation from the drag tests of the metal nets in the tank under five current velocities.The effectiveness and precision of the simulation approach are verified by static and dynamic tests.The proposed simulation approach will provide a good foundation for the further investigation of the hydrodynamic characteristics of deep-sea aquaculture metal cages and the parameter design for the safety of such cage systems.展开更多
In order to investigate the process of incremental sheet forming (ISF) through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the pr...In order to investigate the process of incremental sheet forming (ISF) through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the process and the simulated results were compared with those of experiment. The results of numerical simulations, such as the strain history and distribution, the stress state and distribution, sheet thickness distribution, etc, were discussed in details, and the influences of process parameters on these results were also analyzed. The simulated results of the radial strain and the thickness distribution are in good agreement with experimental results. The simulations reveal that the deformation is localized around the tool and constantly remains close to a plane strain state. With decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces, leading to less thinning and more homogeneous plastic strain and thickness distribution. During ISF, the plastic strain increases stepwise under the action of the tool. Each increase in plastic strain is accompanied by hydrostatic pressure, which explains why obtainable deformation using ISF exceeds the forming limits of conventional sheet forming.展开更多
An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted F...An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted FE elements to EFG domain in analysis. A new scheme to implement adaptive conversion and coupling is presented. The coupling method takes both advantages of finite element method (FEM) and meshless methods. It is capable of handling large deformations with no need of remeshing procedures, while it is computationally more efficient than those full meshless methods. The effectiveness of the proposed method is demonstrated with the numerical simulations of the bulk metal forming processes including forging and extrusion.展开更多
The effect of reinforcement on the solidification of pure metal matrix composites (MMCs) was simulated using a two-dimensional solidification temperature field model by the finite element method. The concept of the ch...The effect of reinforcement on the solidification of pure metal matrix composites (MMCs) was simulated using a two-dimensional solidification temperature field model by the finite element method. The concept of the character length was proposed to describe the size of reinforcement local heat influential zone in MMCs solidification according to the change of the morphologies of solid-liquid interface. The relationship between the character length and the geometrical conditions, the boundary condition and physical properties of the reinforcement were studied, respectively. The results show that the width of the unit and the cold boundary temperature have no effect on the character lengths but have effect on the distance between cold boundary and reinforcement (l) and the thermal parameters of the reinforcement. An experimental rule to predict the value of the character length was derived and applied.展开更多
The one-step finite element method (FEM), based on plastic deformation theory, has been widely used to simulate sheet metal forming processes, but its application in bulk metal forming simulation has been seldom inv...The one-step finite element method (FEM), based on plastic deformation theory, has been widely used to simulate sheet metal forming processes, but its application in bulk metal forming simulation has been seldom investigated, because of the complexity involved. Thus, a bulk metal forming process was analyzed using a rapid FEM based on deformation theory. The material was assumed to be rigid-plastic and strain-hardened. The constitutive relationship between stress and total strain was adopted, whereas the incompressible condition was enforced by penalty function. The geometrical non-linearity in large plastic deformation was taken into consideration. Furthermore, the force boundary condition was treated by a simplified equivalent approach, considering the contact history. Based on constraint variational principle, the deformation FEM was proposed. The one-step forward simulation of axisymmettic upsetting process was performed using this method. The results were compared with those obtained by the traditional incremental FEM to verify the feasibility of the proposed method.展开更多
基金supported by National Natural Science Foundation of China(No. 50175034).
文摘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.
基金Project(50972121) supported by the National Nature Science Foundation of ChinaProject(20080004) supported by the Foundation of Key Laboratory for Advanced Materials Processing Technology,Ministry of Education,China
文摘Extended finite element method(XFEM) is proposed to simulate the discontinuous interface in the liquid-solid forming process.The discontinuous interface is an important phenomenon happening in the liquid-solid forming processes and it is difficult to be simulated accurately with conventional finite element method(CFEM) because it involves solid phase and liquid phase simultaneously.XFEM is becoming more and more popular with the need of solving the discontinuous problem happening in engineering field.The implementation method of XFEM is proposed on Abaqus code by using UEL(user element) with the flowchart.The key is to modify the element stiffness in the proposed method by using UEL on the platform of Abaqus code.In contrast to XFEM used in the simulation of solidification,the geometrical and physical properties of elements were modified at the same time in our method that is beneficial to getting smooth interface transition and precise analysis results.The analysis is simplified significantly with XFEM.
基金Project(50575143)supported by the National Natural Science Foundation of ChinaProject(20040248005)supported by the Specialized Research Fund for the Doctoral Program of Higher Education of China
文摘The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.
文摘A three-dimensional finite element thermal model in direct metal laser sintering(DMLS) including the effect of powder-to-solid transition were established to predict sintering zone, which benefited the determination of suitable process parameters in DMLS. The nonlinear transient model of the metals thermal conductivity for powder-to-solid transition was developed. The model uses solid thermal properties of material in liquid-phase zone, transitional ones in sintering or sintered zone and powder ones in unsintered zones of powder bed to predict, respectively. Sintering zone boundary was estimated by maximum temperature history profile. Experiments were carried out using multi-component Cu-based metal powder. Compared experimental and predicted results, the mean error of sintering depth and width are 7.8% and 14.4%, respectively, which confirms the accuracy of the FEM prediction.
基金financially supported by the National Natural Science Foundation (No. 31572663)
文摘The investigation on hydrodynamic characteristics of a cage is important for its application in the deep-sea aquaculture in our country.With finite element method,the beam element is used to simulate a three-dimensional metal chain net,and the connector element is introduced as the interaction between metal net lines.A mechanical model for the metal net is constructed to simulate the hydrodynamic characteristics of a metal net subjected to fluid current forces.The static simulation results show that the relative errors of the displacements are 2.13%,4.19%,6.64%,and 11.35% compared with static concentrated load tests under concentrated forces of 20,40,60,and 80 N,respectively.Both the transient hydrodynamic deformations and drag forces of the netting structures under different current velocities are obtained by solving the hydrodynamic equation of the netting structure.The average relative error of the current forces obtained by numerical simulations shows an 8.13%deviation from the drag tests of the metal nets in the tank under five current velocities.The effectiveness and precision of the simulation approach are verified by static and dynamic tests.The proposed simulation approach will provide a good foundation for the further investigation of the hydrodynamic characteristics of deep-sea aquaculture metal cages and the parameter design for the safety of such cage systems.
基金Project(50175034) supported by the National Natural Science Foundation of China
文摘In order to investigate the process of incremental sheet forming (ISF) through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the process and the simulated results were compared with those of experiment. The results of numerical simulations, such as the strain history and distribution, the stress state and distribution, sheet thickness distribution, etc, were discussed in details, and the influences of process parameters on these results were also analyzed. The simulated results of the radial strain and the thickness distribution are in good agreement with experimental results. The simulations reveal that the deformation is localized around the tool and constantly remains close to a plane strain state. With decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces, leading to less thinning and more homogeneous plastic strain and thickness distribution. During ISF, the plastic strain increases stepwise under the action of the tool. Each increase in plastic strain is accompanied by hydrostatic pressure, which explains why obtainable deformation using ISF exceeds the forming limits of conventional sheet forming.
基金Project (No. 50575143) supported by the National Natural Science Foundation of China
文摘An adaptive finite element-element-free Galerkin (FE-EFG) coupling method is proposed and developed for the numerical simulation of bulk metal forming processes. This approach is able to adaptively convert distorted FE elements to EFG domain in analysis. A new scheme to implement adaptive conversion and coupling is presented. The coupling method takes both advantages of finite element method (FEM) and meshless methods. It is capable of handling large deformations with no need of remeshing procedures, while it is computationally more efficient than those full meshless methods. The effectiveness of the proposed method is demonstrated with the numerical simulations of the bulk metal forming processes including forging and extrusion.
文摘The effect of reinforcement on the solidification of pure metal matrix composites (MMCs) was simulated using a two-dimensional solidification temperature field model by the finite element method. The concept of the character length was proposed to describe the size of reinforcement local heat influential zone in MMCs solidification according to the change of the morphologies of solid-liquid interface. The relationship between the character length and the geometrical conditions, the boundary condition and physical properties of the reinforcement were studied, respectively. The results show that the width of the unit and the cold boundary temperature have no effect on the character lengths but have effect on the distance between cold boundary and reinforcement (l) and the thermal parameters of the reinforcement. An experimental rule to predict the value of the character length was derived and applied.
基金Sponsored by National Natural Science Foundation of China(50575143)Specialized Research Fund for Doctoral Program of Higher Education of China(20040248005)
文摘The one-step finite element method (FEM), based on plastic deformation theory, has been widely used to simulate sheet metal forming processes, but its application in bulk metal forming simulation has been seldom investigated, because of the complexity involved. Thus, a bulk metal forming process was analyzed using a rapid FEM based on deformation theory. The material was assumed to be rigid-plastic and strain-hardened. The constitutive relationship between stress and total strain was adopted, whereas the incompressible condition was enforced by penalty function. The geometrical non-linearity in large plastic deformation was taken into consideration. Furthermore, the force boundary condition was treated by a simplified equivalent approach, considering the contact history. Based on constraint variational principle, the deformation FEM was proposed. The one-step forward simulation of axisymmettic upsetting process was performed using this method. The results were compared with those obtained by the traditional incremental FEM to verify the feasibility of the proposed method.